U.S. patent number 10,524,963 [Application Number 15/074,650] was granted by the patent office on 2020-01-07 for absorbent article with waist gasketing element and leg cuffs.
This patent grant is currently assigned to The Procter & Gamble Company. The grantee listed for this patent is The Procter & Gamble Company. Invention is credited to Zachary Aaron Freije, Wolfgang Edgar Huhn, Christopher Erin Kiger, Mark James Kline, Cornelia Beate Martynus, Jeromy Thomas Raycheck, Donald Carroll Roe, Abhishek Prakash Surushe.
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United States Patent |
10,524,963 |
Surushe , et al. |
January 7, 2020 |
Absorbent article with waist gasketing element and leg cuffs
Abstract
A disposable absorbent article may include a chassis that
includes a topsheet, a backsheet, and an absorbent core disposed
between the topsheet and the backsheet; and a leg gasketing system
and a waist gasketing element. The leg gasketing system may include
an inner cuff and an outer cuff; the inner cuff may include an
inner cuff folded edge and an inner cuff material edge and the
outer cuff may include an outer cuff folded edge and an outer cuff
material edge such that the web of material is folded laterally
inward to form the outer cuff folded edge and folded laterally
outward to form the inner cuff folded edge. When tested by the
Blowout Method Test as described herein, the disposable absorbent
article has a Blowout Percent Leakage of less than about 9.0%.
Inventors: |
Surushe; Abhishek Prakash
(Schwalbach am Taunus, DE), Raycheck; Jeromy Thomas
(South Lebanon, OH), Freije; Zachary Aaron (Milford, OH),
Martynus; Cornelia Beate (Nidderau-Ostheim, DE), Roe;
Donald Carroll (West Chester, OH), Kiger; Christopher
Erin (Union Township, OH), Huhn; Wolfgang Edgar (Blue
Ash, OH), Kline; Mark James (Okeana, OH) |
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company (Cincinnati, OH)
|
Family
ID: |
55661604 |
Appl.
No.: |
15/074,650 |
Filed: |
March 18, 2016 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160287449 A1 |
Oct 6, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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62134965 |
Mar 18, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61F
13/49011 (20130101); A61F 13/55105 (20130101); A61F
13/496 (20130101); A61F 13/49413 (20130101); A61F
13/49466 (20130101); A61F 13/49 (20130101); A61F
13/4942 (20130101); A61F 13/49406 (20130101); A61F
2013/49092 (20130101) |
Current International
Class: |
A61F
13/494 (20060101); A61F 13/551 (20060101); A61F
13/496 (20060101); A61F 13/49 (20060101) |
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|
Primary Examiner: Anderson; Catharine L
Attorney, Agent or Firm: Albrecht; Daniel S. Gallagher;
William E.
Parent Case Text
CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application
No. 62/134,965, filed Mar. 18, 2015, the substance of which is
incorporated herein by reference.
Claims
What is claimed is:
1. A disposable absorbent article for wearing about the lower torso
of a wearer, the disposable absorbent article comprising: a first
waist region, a second waist region, a crotch region disposed
between the first and second waist regions; a first waist edge and
a second waist edge; and a first longitudinal edge and a second
longitudinal edge; wherein the disposable absorbent article
comprises a chassis comprising: 1.) a topsheet; 2.) a backsheet;
and 3.) an absorbent core disposed between the topsheet and the
backsheet; wherein the disposable absorbent article comprises a leg
gasketing system and at least one waist gasketing element; wherein
the leg gasketing system comprises a web of material forming an
inner cuff and an outer cuff; wherein the inner cuff comprises an
inner cuff folded edge and an inner cuff material edge and the
outer cuff comprises an outer cuff folded edge and an outer cuff
material edge, such that the web of material is folded laterally
inward to form the outer cuff folded edge and folded laterally
outward to form the inner cuff folded edge; wherein at least a
portion of the web of material between the outer cuff folded edge
and the outer cuff material edge is attached to the chassis in the
first waist region, the second waist region, and the crotch region,
wherein at least a portion of the web of material between the inner
cuff folded edge and the outer cuff folded edge is attached to the
web of material between the outer cuff folded edge and the outer
cuff material edge in the crotch region and the first waist region,
and wherein the web of material between the inner cuff folded edge
and the outer cuff folded edge is unattached to the web of material
between the outer cuff folded edge and the outer cuff material edge
in at least a portion of the second waist region, forming a leg
gasketing system pocket with an opening on an inboard longitudinal
edge of the leg gasketing system; wherein the outer cuff has a WVTR
of greater than about 4250 g/m.sup.2/24 hrs; wherein the at least
one waist gasketing element comprises an inboard lateral edge, an
outboard lateral edge, and two longitudinal edges; the at least one
waist gasketing element comprising at least one elastic material;
wherein at least a portion of each of the two longitudinal edges of
the waist gasketing element is attached to the leg gasketing
system; and wherein when tested by a Blowout Method Test as
described herein, the disposable absorbent article has a Blowout
Percent Leakage of less than about 9.0%.
2. The disposable absorbent article of claim 1, wherein the Blowout
Percent Leakage is less than about 7.0%.
3. The disposable absorbent article of claim 1, wherein the Blowout
Percent Leakage is less than about 5.0%.
4. The disposable absorbent article of claim 1, wherein the at
least one elastic material of the waist gasketing element is an
elastic strand.
5. The disposable absorbent article of claim 4, wherein the waist
gasketing element comprises at least four elastic strands.
6. The disposable absorbent article of claim 1, wherein the at
least one elastic material of the waist gasketing element is an
elastic film or an elastomeric nonwoven.
7. The disposable absorbent article of claim 1, wherein the
outboard lateral edge of the waist gasketing element is coterminous
with the second waist edge of the disposable absorbent article.
8. The disposable absorbent article of claim 1, wherein at least a
portion of the inboard lateral edge of the waist gasketing element
is attached to the leg gasketing system.
9. The disposable absorbent article of claim 1, wherein an entire
length of each of the two longitudinal edges of the waist gasketing
element are attached to the leg gasketing system.
10. The disposable absorbent article of claim 1, wherein the waist
gasketing element is attached to the leg gasketing system over
substantially an entire area that the leg gasketing system overlaps
with the waist gasketing element.
11. The disposable absorbent article of claim 1, wherein an
Efficiency Factor is less than about 40.0.
12. The disposable absorbent article of claim 1, wherein an
Efficiency Factor is between about 0.1 and about 25.0.
13. A disposable absorbent article for wearing about the lower
torso of a wearer, the disposable absorbent article comprising: a
first waist region, a second waist region, a crotch region disposed
between the first and second waist regions; a first waist edge and
a second waist edge; and a first longitudinal edge and a second
longitudinal edge; wherein the disposable absorbent article
comprises a chassis comprising:) 1.) a topsheet; 2.) a backsheet;
and 3.) an absorbent core disposed between the topsheet and the
backsheet; wherein the disposable absorbent article comprises a leg
gasketing system and at least one waist gasketing element; wherein
the leg gasketing system comprises a web of material forming an
inner cuff and an outer cuff; wherein the inner cuff comprises an
inner cuff folded edge and an inner cuff material edge and the
outer cuff comprises an outer cuff folded edge and an outer cuff
material edge, such that the web of material is folded laterally
inward to form the outer cuff folded edge and folded laterally
outward to form the inner cuff folded edge; wherein at least a
portion of the web of material between the outer cuff folded edge
and the outer cuff material edge is attached to the chassis in the
first waist region, the second waist region, and the crotch region,
and at least a portion of the web of material between the inner
cuff folded edge and the outer cuff folded edge is attached to the
web of material between the outer cuff folded edge and the outer
cuff material edge in the crotch region and the first waist region;
and the web of material between the inner cuff folded edge and the
outer cuff folded edge is unattached to the web of material between
the outer cuff folded edge and the outer cuff material edge in at
least a portion of the second waist region, forming a leg gasketing
system pocket with an opening on an inboard longitudinal edge of
the leg gasketing system; wherein the outer cuff has a WVTR of
greater than about 4250 g/m.sup.2/24 hrs; wherein the at least one
waist gasketing element comprises an inboard lateral edge, an
outboard lateral edge, and two longitudinal edges; the at least one
waist gasketing element comprising at least one elastic material;
wherein the at least one waist gasketing element is attached to: 1)
the chassis of the disposable absorbent article and 2) the leg
gasketing system, such that at least a portion of the outboard
lateral edge of the waist gasketing element is attached to the
chassis and at least a portion of the outboard lateral edge of the
waist gasketing element is attached to the web of material forming
the leg gasketing system, wherein at least a portion of each of the
two longitudinal edges of the waist gasketing element is attached
to the leg gasketing system, and wherein the inboard lateral edge
of the waist gasketing element is unattached to the chassis of the
disposable absorbent article; and wherein when tested by a Blowout
Method Test as described herein, the disposable absorbent article
has a Blowout Percent Leakage of less than about 9.0%.
14. The disposable absorbent article of claim 13, wherein the
Blowout Percent Leakage is less than about 7.0%.
15. The disposable absorbent article of claim 13, wherein the
Blowout Percent Leakage is less than about 5.0%.
16. The disposable absorbent article of claim 13, wherein the inner
cuff has an opacity of from about 15% to about 50% hunter opacity
and the outer cuff has an opacity of from about 45% to about 75%
hunter opacity.
17. The disposable absorbent article of claim 13, wherein the inner
cuff has an air permeability of less than about 50
m.sup.3/m.sup.2/min and the outer cuff has an air permeability of
greater than about 5 m.sup.3/m.sup.2/min.
18. The disposable absorbent article of claim 13, wherein the inner
cuff has a WVTR of less than about 5500 g/m.sup.2/24 hrs.
19. The disposable absorbent article of claim 13, wherein the leg
gasketing system extends from the first waist edge to the second
waist edge.
20. The disposable absorbent article of claim 13, wherein the at
least one of the leg gasketing system and the at least one waist
gasketing element comprises an N-fiber material.
21. The disposable absorbent article of claim 13, wherein at least
a portion of the inboard lateral edge of the waist gasketing
element is attached to the leg gasketing system.
Description
FIELD OF INVENTION
This invention relates to absorbent articles (e.g., diapers, adult
incontinence articles, feminine hygiene pads) having improved leg
cuffs that yield a more garment-like article, as well as having
improved functional characteristics (e.g., reduced leakage, fecal
material containment).
BACKGROUND OF THE INVENTION
It has long been known that absorbent articles such as conventional
absorbent articles (e.g., diapers, adult incontinence articles,
feminine hygiene pads) offer the benefit of receiving and
containing urine and/or other bodily exudates (e.g., feces, menses,
mixture of feces and urine, mixture of menses and urine, etc.). To
effectively contain bodily exudates, the article should provide a
snug fit around the waist and legs of a wearer.
Current diaper designs frequently include the use of a barrier leg
cuff to prevent leakage of bodily exudates and an outer cuff which
provides a covering over the barrier leg cuff to minimize the
visibility of exudates through the barrier cuff and provide a
secondary means to capture bodily exudates should they breach the
barrier leg cuff. The barrier leg cuff may be made using a
hydrophobic nonwoven and may be disposed on the body-facing surface
of the absorbent article or connected to the body-facing surface of
the film backsheet layer. The barrier leg cuff may be a
substantially liquid impervious layer that prevents bodily exudates
from passing out of the sides of the article and may also be highly
breathable, allowing outside air to reach the skin to help maintain
a healthy level of skin hydration. In many current diapers, the
outer cuff comprises the polymeric film layer of the backsheet to
provide high opacity required to cover the barrier leg cuff as well
as to prevent molten adhesive from passing through the cuff to the
garment-facing surface of the article during manufacturing. The
outer cuff contains the outer leg elastic strands, which create the
contraction forces and gathers, and can be sandwiched between the
cuff material and backsheet material. The elastic strands in the
leg cuffs are typically joined with molten adhesive during
manufacture, and the hot adhesive generally has the potential to
pass through nonwoven materials during manufacture, causing
contamination of manufacturing lines as well as the potential for
stickiness on the outside surface of the article. The polymeric
film generally is used to prevent these issues, however, results in
a plastic-like look as well as a noisy application process.
Because of manufacturing tolerances when cutting, tracking, and
combining materials, the outer leg elastic strands are generally
spaced inboard from the longitudinal edge of the article in the
crotch region. This prevents inadvertent cutting or exposure of the
outer leg elastic strands during the manufacturing process. This
design does not result in the outermost portion of the longitudinal
edge of the product continuously contacting closely to the skin of
the user during wear. Thus, the ability of the elastic strand(s) to
control the edge of the article diminishes as the distance between
the outermost elastic and the edge increases, leading to a more
random distribution of larger gathers which contact the skin at
larger intervals or sometimes not at all. This effect can lead to
user perception that the diaper may leak where the longitudinal
edge does not contact the skin of the user. In addition, many
articles currently available contain only two to three outer leg
elastics per side to create the gathers, increasing the difficulty
of achieving the desired appearance of a wide finished leg cuff or
more garment-like cuff such as the elasticized hemmed edge of the
arm cuff of a sweater. If the elastics are spaced more closely, the
result is a narrow section of elasticized zone, which results in a
less finished, less comfortable, and less clothing-like appearance.
If the elastics are spaced farther apart, the gathers can appear to
separate further from the skin of the user, leading to a perception
of potential leakage risk. As discussed above, this is driven by
having less control of the gathers between strands of increasing
separation.
Accordingly, it is desirable to provide an absorbent article with a
folded outer cuff design having finished edges with elastics that
are close to the edge to maintain a close proximity to the skin to
create improved fit, a more aesthetically pleasing, clothing-like
design and improved leakage protection.
However, even with the improved leakage protection provided by the
cuff designs detailed herein, the most common mode of failure for
absorbent articles still occurs when body exudates leak out of the
gaps between the article and the wearer's legs and/or waist. When
fecal material (e.g., runny bowel movement, a mixture of bowel
movement and urine, etc.) is not absorbed into the topsheet and
core of absorbent article, the fecal material can leak out of the
gaps between the article and the wearer's legs or waist. In
situations where a wearer exudes a higher quantity of fecal
material--which is absorbed by the absorbent core more slowly than
urine--the fecal material may move laterally along the body-side
surface of the absorbent article and reach the barrier leg cuff.
Fecal material may also travel longitudinally along the barrier leg
cuffs or longitudinally up the gluteal grove of the wearer towards
the waist. Due to the movement of the wearer and/or a shortage of
available space under the barrier cuffs and/or within the absorbent
article, the fecal material may leak out of the gaps between the
article and the wearer's legs and/or waist. This results in
soiling, wetting, or otherwise contaminating the wearer's clothing
or other articles (e.g., bedding, furniture, caregiver clothing,
etc.) that come in contact with the wearer's leaky absorbent
article.
Accordingly, it is of continued interest to provide an economically
viable disposable absorbent article with the ability to minimize
the negative effects of bodily extrudate leaks, while also making
it easier to clean the wearer when the soiled disposable absorbent
article is removed. To that end, it is of continued interest to
provide a disposable absorbent article having sufficient retention
capability to safely and cleanly retain bodily extrudate away from
the wearer's clothing and/or skin throughout the expected time of
article use.
SUMMARY OF THE INVENTION
In one aspect, a disposable absorbent article for wearing about the
lower torso of a wearer includes a first waist region, a second
waist region, a crotch region disposed between the first and second
waist regions; a first waist edge and a second waist edge; and a
first longitudinal edge and a second longitudinal edge; wherein the
disposable absorbent article includes a chassis including a
topsheet; a backsheet; and an absorbent core disposed between the
topsheet and the backsheet; wherein the disposable absorbent
article further includes a leg gasketing system and at least one
waist gasketing element; wherein the leg gasketing system includes
a web of material forming an inner cuff and an outer cuff; wherein
the inner cuff includes an inner cuff folded edge and an inner cuff
material edge and the outer cuff comprises an outer cuff folded
edge and an outer cuff material edge, such that the web of material
is folded laterally inward to form the outer cuff folded edge and
folded laterally outward to form the inner cuff folded edge;
wherein the at least one waist gasketing element has an inboard
lateral edge, an outboard lateral edge, and two longitudinal edges;
the at least one waist gasketing element including at least one
elastic material; wherein when tested by a Blowout Method Test as
described herein, the disposable absorbent article has a Blowout
Percent Leakage of less than about 9.0%
In another aspect, a disposable absorbent article for wearing about
the lower torso of a wearer includes a first waist region, a second
waist region, a crotch region disposed between the first and second
waist regions; a first waist edge and a second waist edge; and a
first longitudinal edge and a second longitudinal edge; wherein the
disposable absorbent article includes a chassis including a
topsheet; a backsheet; and an absorbent core disposed between the
topsheet and the backsheet; wherein the disposable absorbent
article further includes a leg gasketing system and at least one
waist gasketing element; wherein the leg gasketing system includes
a web of material forming an inner cuff and an outer cuff; wherein
the inner cuff includes an inner cuff folded edge and an inner cuff
material edge and the outer cuff comprises an outer cuff folded
edge and an outer cuff material edge, such that the web of material
is folded laterally inward to form the outer cuff folded edge and
folded laterally outward to form the inner cuff folded edge;
wherein the at least one waist gasketing element has an inboard
lateral edge, an outboard lateral edge, and two longitudinal edges;
the at least one waist gasketing element including at least one
elastic material; wherein the at least one waist gasketing element
is attached to: 1) the chassis of the disposable absorbent article
and 2) the leg gasketing system, such that at least a portion of
the outboard lateral edge of the waist gasketing element is
attached to the chassis and at least a portion of the outboard
lateral edge of the waist gasketing element is attached to the web
of material forming the leg gasketing system; and wherein the
inboard lateral edge of the waist gasketing element is unattached
to the chassis of the disposable absorbent article; wherein when
tested by a Blowout Method Test as described herein, the disposable
absorbent article has a Blowout Percent Leakage of less than about
9.0%.
The disposable absorbent articles described herein comprise leg
gasketing systems or waist gasketing elements that may comprise one
web or multiple webs of material. The description and claims herein
may refer to leg gasketing system embodiments and waist gasketing
elements that are formed from "a web of material." The recitation
of "a web of material" encompasses a single continuous web of
material, multiple webs of material that are joined together to
become one web of material, or multiple distinct webs of material
that are separate from the disposable absorbent article chassis,
and form part of the leg gasketing system or the waist gasketing
element. The leg gasketing systems and/or waist gasketing elements
described herein may comprise N-fiber material or other non-woven
materials.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of an absorbent article as detailed
herein.
FIG. 2 is a schematic cross sectional view of one of the leg
gasketing systems of FIG. 1, taken along the lateral centerline.
The leg gasketing system is shown in a flat, uncontracted
state.
FIG. 3 is a schematic cross sectional view of the leg gasketing
systems and topsheet of FIG. 1, the cross section taken along the
lateral centerline. The leg gasketing systems are shown in a flat,
uncontracted state.
FIG. 4 is a schematic cross sectional view of the absorbent article
of FIG. 1, the cross section taken along the line A-A.
FIG. 5 is a schematic cross sectional view of the absorbent article
of FIG. 1, the cross section taken along the line B-B.
FIG. 6 is a schematic cross sectional view of the absorbent article
of FIG. 1, the cross section taken along the line C-C.
FIG. 7 is a schematic cross sectional view of the absorbent article
of FIG. 1 with an opacity strengthening patch, the cross section
taken along the line A-A.
FIG. 8 is a schematic cross sectional view of the absorbent article
of FIG. 1 with an opacity strengthening patch, the cross section
taken along the line B-B.
FIG. 9 is a schematic cross sectional view of the absorbent article
of FIG. 1 with an opacity strengthening patch, the cross section
taken along the line C-C.
FIG. 10 is a schematic cross sectional view of an exemplary
absorbent article as described herein.
FIGS. 11A-T are schematic cross sectional views of the leg
gasketing systems suitable for use in the absorbent articles
detailed herein.
FIG. 12 is a schematic plan view of an absorbent article as
detailed herein. FIG. 12 is substantially identical to the
absorbent article of FIG. 1, with the addition of a waist gasketing
element in the second waist region.
FIG. 13 is a close-up schematic plan view of the second waist
region of the absorbent article depicted in FIG. 12.
FIG. 14 is a schematic cross sectional view of the absorbent
article of FIG. 13, the cross section taken along the longitudinal
centerline.
FIG. 15 is a schematic cross sectional view of the absorbent
article of FIG. 13, the cross section taken along the line D-D.
FIG. 16 is a schematic cross sectional view of the absorbent
article of FIG. 13, the cross section taken along the line E-E.
FIG. 17 is a schematic cross sectional view of the absorbent
article of FIG. 13, the cross section taken along the line D-D.
FIG. 18 is a schematic cross sectional view of the absorbent
article of FIG. 13, the cross section taken along the line E-E.
FIG. 19 is a perspective view of the trough used in the Blowout
Method Test described herein.
FIG. 20 is a perspective view of the ball with a transverse axle
used in the Blowout Method Test described herein.
FIG. 21 is a schematic cross sectional view of a package of
absorbent articles as detailed herein.
DETAILED DESCRIPTION OF THE INVENTION
Definitions:
As used herein, the following terms shall have the meaning
specified thereafter:
"Disposable," in reference to absorbent articles, means that the
absorbent articles are generally not intended to be laundered or
otherwise restored or reused as absorbent articles (i.e., they are
intended to be discarded after a single use and, preferably, to be
recycled, composted or otherwise discarded in an environmentally
compatible manner).
"Absorbent article" refers to devices which absorb and contain body
exudates and, more specifically, refers to devices which are placed
against or in proximity to the body of the wearer to absorb and
contain the various exudates discharged from the body. Exemplary
absorbent articles include diapers, training pants, pull-on
pant-type diapers (i.e., a diaper having a pre-formed waist opening
and leg openings such as illustrated in U.S. Pat. No. 6,120,487),
refastenable diapers or pant-type diapers, incontinence briefs and
undergarments, diaper holders and liners, feminine hygiene garments
such as panty liners, absorbent inserts, and the like.
"Proximal" and "Distal" refer respectively to the location of an
element relatively near to or far from the longitudinal or lateral
centerline of a structure (e.g., the proximal edge of a
longitudinally extending element is located nearer to the
longitudinal centerline than the distal edge of the same element is
located relative to the same longitudinal centerline).
"Body-facing" and "garment-facing" refer respectively to the
relative location of an element or a surface of an element or group
of elements. "Body-facing" implies the element or surface is nearer
to the wearer during wear than some other element or surface.
"Garment-facing" implies the element or surface is more remote from
the wearer during wear than some other element or surface (i.e.,
element or surface is proximate to the wearer's garments that may
be worn over the disposable absorbent article).
"Longitudinal" refers to a direction running substantially
perpendicular from a waist edge to an opposing waist edge of the
article and generally parallel to the maximum linear dimension of
the article. Directions within 45 degrees of the longitudinal
direction are considered to be "longitudinal"
"Lateral" refers to a direction running from a longitudinal edge to
an opposing longitudinal edge of the article and generally at a
right angle to the longitudinal direction. Directions within 45
degrees of the lateral direction are considered to be
"lateral."
"Disposed" refers to an element being located in a particular place
or position.
"Joined" refers to configurations whereby an element is directly
secured to another element by affixing the element directly to the
other element and to configurations whereby an element is
indirectly secured to another element by affixing the element to
intermediate member(s) which in turn are affixed to the other
element.
"Film" refers to a sheet-like material wherein the length and width
of the material far exceed the thickness of the material.
Typically, films have a thickness of about 0.5 mm or less.
"Water-permeable" and "water-impermeable" refer to the
penetrability of materials in the context of the intended usage of
disposable absorbent articles. Specifically, the term
"water-permeable" refers to a layer or a layered structure having
pores, openings, and/or interconnected void spaces that permit
liquid water, urine, or synthetic urine to pass through its
thickness in the absence of a forcing pressure. Conversely, the
term "water-impermeable" refers to a layer or a layered structure
through the thickness of which liquid water, urine, or synthetic
urine cannot pass in the absence of a forcing pressure (aside from
natural forces such as gravity). A layer or a layered structure
that is water-impermeable according to this definition may be
permeable to water vapor, i.e., may be "vapor-permeable."
"Extendibility" and "extensible" mean that the width or length of
the component in a relaxed state can be extended or increased.
"Elasticated" and "elasticized" mean that a component comprises at
least a portion made of elastic material.
"Elongatable material," "extensible material," or "stretchable
material" are used interchangeably and refer to a material that,
upon application of a biasing force, can stretch to an elongated
length of at least about 110% of its relaxed, original length (i.e.
can stretch to 10 percent more than its original length), without
rupture or breakage, and upon release of the applied force, shows
little recovery, less than about 20% of its elongation without
complete rupture or breakage as measured by EDANA method 20.2-89.
In the event such an elongatable material recovers at least 40% of
its elongation upon release of the applied force, the elongatable
material will be considered to be "elastic" or "elastomeric." For
example, an elastic material that has an initial length of 100 mm
can extend at least to 150 mm, and upon removal of the force
retracts to a length of at least 130 mm (i.e., exhibiting a 40%
recovery). In the event the material recovers less than 40% of its
elongation upon release of the applied force, the elongatable
material will be considered to be "substantially non-elastic" or
"substantially non-elastomeric". For example, an elongatable
material that has an initial length of 100 mm can extend at least
to 150 mm, and upon removal of the force retracts to a length of at
least 145 mm (i.e., exhibiting a 10% recovery).
"Elastomeric material" is a material exhibiting elastic properties.
Elastomeric materials may include elastomeric films, scrims,
nonwovens, and other sheet-like structures.
"Pant" refers to disposable absorbent articles having a pre-formed
waist and leg openings. A pant may be donned by inserting a
wearer's legs into the leg openings and sliding the pant into
position about the wearer's lower torso. Pants are also commonly
referred to as "closed diapers", "prefastened diapers", "pull-on
diapers", "training pants" and "diaper-pants."
Absorbent Article:
The present disclosure is directed to a disposable absorbent
article with a leg gasketing system that comprises a folded outer
cuff having neatly finished outer cuff folded edges that creates an
aesthetically pleasing design that is garment like, the absorbent
article also including a leg gasketing system pocket with an
opening towards the interior of the article, wherein the pocket
reduces runny bowel movement leaks, the absorbent article also
including at least one waist gasketing element. The folded outer
cuff design is advantageous in preventing penetration and adhesive
bleedthrough without the use of a polymeric film layer in the
elasticized region. The absorbent article may comprise an opacity
strengthening patch to provide the strength needed to prevent the
article from extending excessively during application and wearing,
and provide the opacity at the sides and waist to prevent the skin
of the user from showing through the article.
FIGS. 1 and 12 are plan views of the absorbent article 20 described
herein in a flat, uncontracted state. FIGS. 1 and 12 illustrate
substantially the same disposable absorbent article, with the
difference being that FIG. 12 also incorporates a waist gasketing
element 81 in the second waist region 38. Accordingly, when
detailing the particular elements of the absorbent article of FIG.
1 herein, the same disclosure will also apply to the absorbent
article of FIG. 12, as those same elements may also be present in
the absorbent article of FIG. 12 (whether explicitly shown or not).
Due to clarity issues, some of the elements that are explicitly
shown and referenced in FIG. 1 may appear missing from FIG. 12. For
instance, the cuff separation bonds 45 are not explicitly shown in
outboard part of the second waist region 38 of FIG. 12 due to
providing clarity to the illustration of the waist gasketing
element 81. However, even though not explicitly illustrated, the
absorbent article of FIG. 12 may include cuff separation bonds 45
in that region as detailed in FIG. 1 and described herein, as well
as any other elements illustrated in FIG. 1 (or the figures that
reference FIG. 1) and/or described herein.
The garment-facing surface 120 of the absorbent article 20 is
facing the viewer. The absorbent article 20 includes a longitudinal
centerline 100 and a lateral centerline 110. The absorbent article
20 may comprise a chassis 22. The absorbent article 20 and chassis
22 are shown to have a first waist region 36, a second waist region
38 opposed to the first waist region 36, and a crotch region 37
located between the first waist region 36 and the second waist
region 38. The waist regions 36 and 38 generally comprise those
portions of the absorbent article 20 which, when worn, encircle the
waist of the wearer. The waist regions 36 and 38 may include
elastic elements such that they gather about the waist of the
wearer to provide improved fit and containment. The crotch region
37 is the portion of the absorbent article 20 which, when the
absorbent article 20 is worn, is generally positioned between the
legs of the wearer.
The outer periphery of chassis 22 is defined by longitudinal edges
12 and waist edges (first waist edge 13 in first waist region 36
and second waist edge 14 in second waist region 38). The
longitudinal edges 12 may be subdivided into a front longitudinal
edge 12a, which is the portion of the longitudinal edge 12 in the
first waist region 36, and a rear longitudinal edge 12b, which is
the portion of the longitudinal edge 12 in the rear waist region
38. The chassis 22 may have opposing longitudinal edges 12 that are
oriented generally parallel to the longitudinal centerline 100.
However, for better fit, longitudinal edges 12 may be curved or
angled to produce, for example, an "hourglass" shape diaper when
viewed in a plan view. The chassis 22 may have opposing lateral
edges 14 that are oriented generally parallel to the lateral
centerline 110.
The chassis 22 may comprise a liquid permeable topsheet 24, a
backsheet 26, and an absorbent core 28 between the topsheet 24 and
the backsheet 26. In absorbent articles that include one or more
opacity strengthening patches 80, the chassis 22 also comprises the
opacity strengthening patch(s). The absorbent core 28 may have a
body-facing surface and a garment facing-surface. The topsheet 24
may be joined to the core 28 and/or the backsheet 26. The backsheet
26 may be joined to the core 28 and/or the topsheet 24. It should
be recognized that other structures, elements, or substrates may be
positioned between the core 28 and the topsheet 24 and/or backsheet
26. The chassis 22 may comprise the main structure of the absorbent
article 20 with other features may added to form the composite
absorbent article structure. While the topsheet 24, the backsheet
26, and the absorbent core 28 may be assembled in a variety of
well-known configurations, preferred absorbent article
configurations are described generally in U.S. Pat. Nos. 3,860,003;
5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and
6,004,306.
Topsheet:
The topsheet 24 is generally a portion of the absorbent article 20
that may be positioned at least in partial contact or close
proximity to a wearer. Suitable topsheets 24 may be manufactured
from a wide range of materials, such as porous foams; reticulated
foams; apertured plastic films; or woven or nonwoven webs of
natural fibers (e.g., wood or cotton fibers), synthetic fibers
(e.g., polyester or polypropylene fibers), or a combination of
natural and synthetic fibers. The topsheet 24 is generally supple,
soft feeling, and non-irritating to a wearer's skin. Generally, at
least a portion of the topsheet 24 is liquid pervious, permitting
liquid to readily penetrate through the thickness of the topsheet
24. One topsheet 24 useful herein is available from BBA Fiberweb,
Brentwood, Tenn. as supplier code 055SLPV09U.
Any portion of the topsheet 24 may be coated with a lotion or skin
care composition as is known in the art. Examples of suitable
lotions include those described in U.S. Pat. Nos. 5,607,760;
5,609,587; 5,635,191; and 5,643,588. The topsheet 24 may be fully
or partially elasticized or may be foreshortened so as to provide a
void space between the topsheet 24 and the core 28. Exemplary
structures including elasticized or foreshortened topsheets are
described in more detail in U.S. Pat. Nos. 4,892,536; 4,990,147;
5,037,416; and 5,269,775.
Absorbent Core:
The absorbent core 28 may comprise a wide variety of
liquid-absorbent materials commonly used in disposable diapers and
other absorbent articles. Examples of suitable absorbent materials
include comminuted wood pulp, which is generally referred to as air
felt creped cellulose wadding; melt blown polymers, including
co-form; chemically stiffened, modified or cross-linked cellulosic
fibers; tissue, including tissue wraps and tissue laminates;
absorbent foams; absorbent sponges; superabsorbent polymers;
absorbent gelling materials; or any other known absorbent material
or combinations of materials. At least a portion of the absorbent
core may be substantially cellulose free and contains less than 10%
by weight cellulosic fibers, less than 5% cellulosic fibers, less
than 1% cellulosic fibers, no more than an immaterial amount of
cellulosic fibers or no cellulosic fibers. It should be understood
that an immaterial amount of cellulosic material does not
materially affect at least one of the thinness, flexibility, and
absorbency of the portion of the absorbent core that is
substantially cellulose free. Among other benefits, it is believed
that when at least a portion of the absorbent core is substantially
cellulose free, this portion of the absorbent core is significantly
thinner and more flexible than a similar absorbent core that
includes more than 10% by weight of cellulosic fibers. The amount
of absorbent material, such as absorbent particulate polymer
material present in the absorbent core may vary, but in certain
absorbent articles, is present in the absorbent core in an amount
greater than about 80% by weight of the absorbent core, or greater
than about 85% by weight of the absorbent core, or greater than
about 90% by weight of the absorbent core, or greater than about
95% by weight of the core.
Exemplary absorbent structures for use as the absorbent core 28 are
described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735;
4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207;
5,397,316; and 5,625,222.
Backsheet:
The backsheet 26 is generally positioned such that it may be at
least a portion of the garment-facing surface 120 of the absorbent
article 20. Backsheet 26 may be designed to prevent the exudates
absorbed by and contained within the absorbent article 20 from
soiling articles that may contact the absorbent article 20, such as
bed sheets and undergarments. The backsheet 26 may be substantially
water-impermeable. Suitable backsheet 26 materials include films
such as those manufactured by Tredegar Industries Inc. of Terre
Haute, Ind. and sold under the trade names X15306, X10962, and
X10964. Other suitable backsheet 26 materials may include
breathable materials that permit vapors to escape from the
absorbent article 20 while still preventing exudates from passing
through the backsheet 26. Exemplary breathable materials may
include materials such as woven webs, nonwoven webs, composite
materials such as film-coated nonwoven webs, and microporous films
such as manufactured by Mitsui Toatsu Co., of Japan under the
designation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,
under the designation EXXAIRE.
Suitable breathable composite materials comprising polymer blends
are available from Clopay Corporation, Cincinnati, Ohio under the
name HYTREL blend P18-3097. Such breathable composite materials are
described in greater detail in PCT Application No. WO 95/16746 and
U.S. Pat. No. 5,865,823. Other breathable backsheets including
nonwoven webs and apertured formed films are described in U.S. Pat.
No. 5,571,096. An exemplary, suitable backsheet is disclosed in
U.S. Pat. No. 6,107,537. Other suitable materials and/or
manufacturing techniques may be used to provide a suitable
backsheet 26 including, but not limited to, surface treatments,
particular film selections and processing, particular filament
selections and processing, etc.
Backsheet 26 may also consist of more than one layer. The backsheet
26 may comprise an outer cover and an inner layer. The outer cover
may be made of a soft, non-woven material. The inner layer may be
made of a substantially liquid-impermeable film. The outer cover
and an inner layer may be joined together by adhesive or any other
suitable material or method. A particularly suitable outer cover is
available from Corovin GmbH, Peine, Germany as supplier code
A18AHO, and a particularly suitable inner layer is available from
RKW Gronau GmbH, Gronau, Germany as supplier code PGBR4WPR. While a
variety of backsheet configurations are contemplated herein, it
would be obvious to those skilled in the art that various other
changes and modifications can be made without departing from the
spirit and scope of the invention.
Ears/Fasteners:
The absorbent article 20 may include front ears 40 and/or back ears
42. The ears 40, 42 may be extensible, inextensible, elastic, or
inelastic. The ears 40, 42 may be formed from nonwoven webs, woven
webs, knitted fabrics, polymeric and elastomeric films, apertured
films, sponges, foams, scrims, and combinations and laminates
thereof. The ears 40, 42 may be formed of a stretch laminate such
as a nonwoven/elastomeric material laminate or a
nonwoven/elastomeric material/nonwoven laminate. Stretch laminates
may be formed by any method known in the art. For example, the ears
40, 42 may be formed as a zero strain stretch laminate, which
includes at least a layer of non-woven material and an elastomeric
element. The elastomeric element is attached to the layer of
non-woven material while in a relaxed or substantially relaxed
state, and the resulting laminate is made stretchable (or more
stretchable over a further range) by subjecting the laminate to an
activation process which elongates the nonwoven layer permanently,
but the elastomeric element temporarily. The nonwoven layer may be
integral with at least a portion of the chassis 22, in which case
the elastomeric element may be attached to the nonwoven layer and
the non-woven/elastomeric element laminate is subsequently
activated. Alternatively, the nonwoven layer may be a separate
component, in which case the elastomeric element is attached to the
nonwoven layer to form the laminate, which is then coupled to the
main portion. If one or more layers of the side panel are provided
separately, the laminate may be activated either before or after
attachment to the main portion. The zero strain activation
processes is further disclosed in U.S. Pat. Nos. 5,167,897 and
5,156,793. A suitable elastic ear may be an activated laminate
comprising an elastomeric film (such as is available from Tredegar
Corp, Richmond, Va., as supplier code X25007) disposed between two
nonwoven layers (such as is available from BBA Fiberweb, Brentwood,
Tenn. as supplier code FPN332).
The ears 40, 42 may be discrete or integral. A discrete ear is
formed as separate element which is joined to the chassis 22. An
integral ear is a portion of the chassis 22 that projects laterally
outward from the longitudinal edge 12. The integral ear may be
formed by cutting the chassis form to include the shape of the ear
projection.
The absorbent article 20 may also include a fastening system 50.
When fastened, the fastening system 50 interconnects the first
waist region 36 and the rear waist region 38 resulting in a waist
circumference that may encircle the wearer during wear of the
absorbent article 20. The fastening system 50 may comprises a
fastener such as tape tabs, hook and loop fastening components,
interlocking fasteners such as tabs & slots, buckles, buttons,
snaps, and/or hermaphroditic fastening components, although any
other known fastening means are generally acceptable. Some
exemplary surface fastening systems are disclosed in U.S. Pat. Nos.
3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527; 5,151,092;
and 5,221,274. An exemplary interlocking fastening system is
disclosed in U.S. Pat. No. 6,432,098. The fastening system 50 may
also provide a means for holding the article in a disposal
configuration as disclosed in U.S. Pat. No. 4,963,140. The
fastening system 50 may also include primary and secondary
fastening systems, as disclosed in U.S. Pat. No. 4,699,622. The
fastening system 50 may be constructed to reduce shifting of
overlapped portions or to improve fit as disclosed in U.S. Pat.
Nos. 5,242,436; 5,499,978; 5,507,736; and 5,591,152.
Leg Gasketing System:
The absorbent article 20 may include a leg gasketing system 70 that
is attached to the chassis 22. FIGS. 2 and 3 depict schematic cross
sectional views of the exemplary leg gasketing system of FIG. 1 in
a flat, uncontracted state, the views taken through the lateral
centerline 110 (FIG. 2 is a schematic cross section of the left leg
gasketing system, and FIG. 3 is a schematic cross section of both
leg gasketing systems in relation to the topsheet). FIGS. 4-9 also
depict schematic cross sectional views of the exemplary leg
gasketing system 70 of FIG. 1. FIGS. 4-6 are cross sections of a
version of the disposable absorbent article of FIG. 1 without an
opacity strengthening patch 80, and FIGS. 7-9 are cross sections of
a version of the disposable absorbent article of FIG. 1 with an
opacity strengthening patch 80. In the article of FIGS. 7-9, the
opacity strengthening patches 80 are located in the four corners of
the diaper chassis 22, overlapping portions of both the polymeric
film inner layer of the backsheet 26 and the ears 40, 42. FIGS. 4
and 7 are schematic cross sectional views through line A-A of FIG.
1. FIGS. 5 and 8 are schematic cross sectional views through line
B-B of FIG. 1. FIGS. 6 and 9 are schematic cross sectional views
through line C-C of FIG. 1. In the various articles, the leg
gasketing system 70 may include an inner cuff 71 that has an inner
cuff folded edge 72 and an inner cuff material edge 73. The leg
gasketing system 70 may further include an outer cuff 74 that has
an outer cuff folded edge 75 and an outer cuff material edge
76.
Each leg gasketing system 70 may comprise a single, continuous web
of material. An leg gasketing system having a single web of
material may provide a cost advantage over leg gasketing systems
having more than one web of material. Further, a leg gasketing
system formed from one web of material may have fewer leaks, as
there are no holes created by bonding more than one web of
material. Also, a leg gasketing system having one web of material
may be more aesthetically pleasing, as few mechanical bonds are
visible. The leg gasketing system 70 may be formed from more than
one web of material (e.g., multiple webs of material that are
joined together to become one web of material, or multiple distinct
webs of material that are separate from the disposable absorbent
article chassis and form part of the leg gasketing system). Herein,
locations (e.g., folded edge, material edge, etc.) on the leg
gasketing system 70 are detailed in reference to "a web of
material" or "a portion of the web of material." The recitations of
"a web of material" or "the web of material" refer to leg gasketing
systems that may be formed from a single, continuous web of
material, multiple webs of material that are joined together to
become one web of material, or multiple distinct webs of material
that are separate from the disposable absorbent article chassis and
form part of the leg gasketing system. All such leg gasketing
systems are contemplated.
The leg gasketing system 70 may include an inner cuff 71 that has
an inner cuff folded edge 72 and an inner cuff material edge 73.
The leg gasketing system 70 may further include an outer cuff 74
that has an outer cuff folded edge 75 and an outer cuff material
edge 76. The web of material may be folded laterally inward (toward
the longitudinal centerline 100 of the absorbent article 20) to
form the outer cuff folded edge 75 and folded laterally outward
(away from the longitudinal centerline 100 of the absorbent article
20) to form the inner cuff folded edge 72.
At least a portion of the web of material between the outer cuff
folded edge 75 and the outer cuff material edge 76 may be attached
to the chassis 22 (e.g., the topsheet 24, the backsheet 26, and/or
the opacity strengthening patch 80) in the first waist region 36,
the second waist region 38 and the crotch region 37. The attachment
to the chassis 22 is made through utilization of one or more cuff
attachment bonds 43, 44. One or more of the cuff attachment bonds
43, 44 may be continuous, or substantially continuous (e.g., in a
continuously intermittent pattern) from the first waist edge 13 to
the second waist edge 14. As seen in the exemplary article of FIGS.
3-6, a first cuff attachment bond 43 attaches at least a portion of
the web of material between the outer cuff folded edge 75 and the
outer cuff material edge 76 to the topsheet 24. And a second cuff
attachment bond 44 attaches at least a portion of the web of
material between the outer cuff folded edge 75 and the outer cuff
material edge 76 to the inner layer of backsheet 26 (e.g.,
backsheet film). In FIGS. 3-6, a single first cuff attachment bond
43 and a single second cuff attachment bond 44 are shown, but
articles having multiple first cuff attachment bonds 43 and/or
multiple second cuff attachment bonds 44 are contemplated. As seen
in FIGS. 7-9, a first cuff attachment bond 43 attaches at least a
portion of the web of material between the outer cuff folded edge
75 and the outer cuff material edge 76 to the topsheet 24. And at
least one second cuff attachment bond 44 attaches at least a
portion of the web of material between the outer cuff folded edge
75 and the outer cuff material edge 76 to the opacity strengthening
patch 80 in at least a portion of the first waist region 36 and at
least a portion of the second waist region 38. The opacity
strengthening patch is attached to the inner layer of backsheet 26
(e.g., backsheet film) by at least one OSP bond(s) 46. In the
crotch region 37 and in a portion of the first waist region 36 and
in a portion of the second waist region 38, at least a portion of
the web of material between the outer cuff folded edge 75 and the
outer cuff material edge 76 is attached to the backsheet 26 (inner
or outer backsheet layer) through cuff attachment bond 44. In other
words, from first waist edge 13 to second waist edge 14, at least a
portion of the web of material between the outer cuff folded edge
75 and the outer cuff material edge 76 is attached to either the
backsheet 26 or to the opacity strengthening patch 80 through
continuous or substantially continuous second cuff attachment
bond(s) 44. In FIGS. 7-9, a single first cuff attachment bond 43 is
shown, but articles having multiple first cuff attachment bonds 43
are contemplated. The cuff attachment bonds 43, 44 and the OSP
bonds 46 may take the form of glue, heat bond, pressure bond, CPW
bonds, or any other bonding method known in the art. In FIGS. 3-9,
the cuff attachment bonds 43, 44 and the OSP bonds 46 take the form
of a glue bond.
Further, at least a portion of the web material between the inner
cuff folded edge 72 and the outer cuff folded edge 75 is attached
to at least a portion of the web of material between the outer cuff
folded edge 75 and the outer cuff material edge 76 in at least the
crotch region 37 and the first waist region 36. The attachment of
the web of material between the inner cuff folded edge 72 and the
outer cuff folded edge 75 to the web of material between the outer
cuff folded edge 75 and the outer cuff material edge 76 in at least
the crotch region 37 and the first waist region 36 is made through
utilization of one or more cuff separation bonds 45. As seen in
FIGS. 1-9, the cuff separation bond attaches at least a portion of
the web material between the inner cuff folded edge 72 and the
outer cuff folded edge 75 to the web of material between the outer
cuff folded edge 75 and the outer cuff material edge 76 in the
crotch region 37, the first waist region 36, and a portion of the
second waist region 38. The cuff separation bond 45 may take the
form of glue, heat bond, pressure bond, CPW bonds, or any other
bonding method known in the art. In FIGS. 3-9, the cuff separation
bond 45 takes the form of a glue bond.
As illustrated in FIGS. 1 and 4-9, the web of material between the
inner cuff folded edge 72 and the outer cuff folded edge 75 is
unattached to the web of material between the outer cuff folded
edge 75 and the outer cuff material edge 76 in at least a portion
of the second waist region 38. Due to the web of material between
the inner cuff folded edge 72 and the outer cuff folded edge 75
being unattached to the web of material between the outer cuff
folded edge 75 and the outer cuff material edge 76 in at least a
portion of the second waist region 38, a leg gasketing system
pocket 47 is formed in at least a portion of the second waist
region of the leg gasketing system 70. The leg gasketing system
pocket 47 includes an inboard longitudinal edge 48 and an outboard
longitudinal edge 49, which define lateral dimensions of the leg
gasketing system pocket. The inboard longitudinal edge 48 of the
leg gasketing system pocket 47 may be coterminous with a line that
the cuff separation bond 45 runs along in the longitudinal
direction. The outboard longitudinal edge 49 may be coterminous
with the outer cuff folded edge 75. Alternately, the outboard
longitudinal edge 49 may be coterminous with the most outboard bond
of the outer cuff 74.
The leg gasketing system pocket 47 may include an opening 51 which
runs a distance along the inboard longitudinal edge 48 of the leg
gasketing system pocket 47. The opening 51 is created by a break in
the cuff separation bond 45. Referring to FIG. 1, the cuff
separation bond 45 runs in the longitudinal direction of the
absorbent article, and is continuous, or substantially continuous
(e.g., in a continuously intermittent pattern) in the first waist
region 36 and the crotch region 37. The continuous cuff separation
bond 45 continues into the second waist region 38, but then stops
for a defined distance and then starts again along the same
longitudinal line. The distance in which the cuff separation bond
45 stops along that longitudinal line is the distance in which the
web material between the inner cuff folded edge 72 and the outer
cuff folded edge 75 is unattached to the web of material between
the outer cuff folded edge 75 and the outer cuff material edge 76.
Accordingly, this distance is the length of the opening 51 which
runs along the inboard longitudinal edge 48 of the leg gasketing
system pocket 47. The opening 51 has an inboard lateral edge 52 and
an outboard lateral edge 53 where the cuff separation bond 45
starts and stops along the longitudinal line that the cuff
separation bond 45 runs along. As illustrated in FIG. 1, the length
of the opening 51 can be determined by measuring the distance
between inboard lateral edge 52 and outboard lateral edge 53, taken
along the longitudinal line that the cuff separation bond 45 runs
along.
The leg gasketing system pocket 47 may include an opening 51 which
again runs a distance along the inboard longitudinal edge 48 of the
leg gasketing system pocket 47. The opening 51 is created by a
series of breaks in the cuff separation bond 45. Referring to FIG.
1, the cuff separation bond 45 runs in the longitudinal direction
of the absorbent article, and is continuous in the first waist
region 36 and the crotch region 37. The continuous cuff separation
bond 45 continues into the second waist region 38, but then becomes
an intermittent bond pattern (e.g., stop-start-stop-start) for a
defined distance and then becomes continuous again along the same
longitudinal line. The distance in which the cuff separation bond
45 becomes an intermittent bond pattern along that longitudinal
line is the distance in which the web material between the inner
cuff folded edge 72 and the outer cuff folded edge 75 is
intermittently attached to the web of material between the outer
cuff folded edge 75 and the outer cuff material edge 76. This
intermittent pattern for a distance of the cuff separation bond 45
creates series of small pockets, together referred to herein as a
leg gasketing system pocket.
The pocket and opening can occur in the first waist region, the
second waist region, or in the crotch region as needed for the
specific type of exudates and the particular situation where
leakage prevention is desired. For instance, a wearer who sleeps on
their belly (front) may benefit from the pocket and opening being
located in the front waist region, as to stop urine leakage out of
the front waist during sleep. Likewise, it may be important to
create the opening on the crotch region for users wearing the
article in the standing position as to contain exudates that are
likely to locate centrally in the article due to the force of
gravity when in a standing position.
The opening 51 may measure between about 5 mm and about 100 mm in
the longitudinal direction, or any range or distance within the
range of about 5 mm to about 100 mm; in some articles the opening
measures about 75 mm or about 50 mm; and in other articles the
opening measures between about 1 mm and about 20 mm. The length of
opening 51 may be between about 1% and about 75% of the overall
longitudinal length of the leg gasketing system pocket 47 (or any
range or percentage within the range of about 1% to about 75%). The
overall longitudinal length of the leg gasketing system pocket 47
is the distance from the furthest longitudinally inboard portion of
the pocket to the furthest longitudinally outboard portion of the
pocket. As shown in FIG. 1, the overall longitudinal length of the
leg gasketing system pocket 47 is the distance from the inboard
lateral edge 52 of the opening 51 to the second waist edge 14 of
the absorbent article 20, taken along the longitudinal line that
the cuff separation bond 45 runs along. In other words, for the
article shown in FIG. 1, the longitudinal dimensions of the leg
gasketing system pocket 47 are defined by the inboard lateral edge
52 of the opening 51 and the second waist edge 14. The overall
longitudinal length of the leg gasketing system pocket 47 may
measure between about 5 mm and about 200 mm in the longitudinal
direction, or any range or distance within the range of about 5 mm
to about 200 mm; in some articles, about 100 mm, about 75 mm or
about 50 mm; and alternately the overall longitudinal length
measures between about 1 mm and about 20 mm.
The overall lateral width of the leg gasketing system pocket 47 is
the distance from the furthest laterally inboard portion of the
pocket to the furthest laterally outboard portion of the pocket.
For the article shown in FIG. 1, the overall lateral width of the
leg gasketing system pocket 47 is the distance from the inboard
longitudinal edge 48 of the leg gasketing system pocket to the
outboard longitudinal edge 49 of the leg gasketing system pocket,
taken along a line that is parallel to the second waist edge 14 and
centered in the middle of the opening 51 of the leg gasketing
system pocket. In other words, for the exemplary article shown in
FIG. 1, the lateral dimension of the leg gasketing system pocket 47
(i.e., the width) is defined by inboard and outboard longitudinal
edges 48, 49 of the leg gasketing system pocket 47. The overall
lateral width of the leg gasketing system pocket 47 may measure
between about 5 mm and about 60 mm in the lateral direction, or any
range or distance within the range of about 5 mm to about 60 mm; in
some articles, about 30 mm, about 25 mm, or about 20 mm; and in
other articles, the overall lateral width measures between about 1
mm and about 20 mm. The overall lateral width of the leg gasketing
system pocket 47 may be between about 1% and about 75% of the
overall longitudinal length of the leg gasketing system pocket 47
(or any range or percentage within the range of about 1% to about
75%). The length of opening 51 may be between about 20% and about
100% of the overall lateral width of the leg gasketing system
pocket 47 (or any range or percentage within the range of about 20%
to about 100%).
When a wearer of an absorbent article has a runny bowel movement,
many times the runny bowel movement spreads upon defecation and
leaks out of the absorbent article in an area between the leg cuffs
and wearer's legs, or in an area between the waist region and the
wearer's back. Leaks of this type often happen because the snug fit
between user's body and the attached absorbent article do not allow
enough room for the runny bowel movement to remain contained within
the absorbent article during the wearer's movement. One advantage
of the leg gasketing system pocket 47 as detailed herein, in
combination with the leg gasketing system(s) as detailed herein,
are the additional pocketed areas that provide extra void volumes
within the leg cuffs for containment of bodily extrudate (e.g.,
fecal material). When the wearer moves, a portion of the bodily
extrudate will migrate into the leg gasketing system pocket 47 for
containment and be held/trapped between two layers of nonwoven
within the leg gasketing system before it can leak out in an area
between the wearer's back and the back waist region of the
absorbent article or an area between the leg cuffs and wearer's
legs of the absorbent article. Thus, the leg gasketing system
pocket 47 detailed herein reduces leaks. Moreover, leg gasketing
system pocket 47 provides additional void volume within the leg
cuffs to receive the fecal material which helps in isolating the
fecal material from wearer's skin and restricts flow towards the
front by the separation sheet.
The leg gasketing system pocket 47 may be free of elastic members
77. The leg gasketing system pocket 47 may contain one or more snap
back elastic members. The leg gasketing system pocket 47 may have a
second opening 55 along the second waist edge 14 of the absorbent
article. The leg gasketing system pocket 47 may be sealed along the
second waist edge 14.
At least a portion of the web of material between the outer cuff
folded edge 75 and the outer cuff material edge 76 may be attached
to the chassis 22 (e.g., topsheet 24, backsheet 26, and/or opacity
strengthening patch 80) in the first waist region 36, the second
waist region 38 and the crotch region 37; and at least a portion of
the web of material between the inner cuff folded edge 72 and the
outer cuff folded edge 75 may be attached to the web of material
between the outer cuff folded edge 75 and the outer cuff material
edge 76 in the crotch region 37 and the first waist region 36;
wherein the outer cuff includes an elastics adhesive 79 and at
least one longitudinally oriented elastic member running parallel
to the outer cuff folded edge 75, the elastics adhesive 79 and at
least one elastic member disposed between 1) the web of material
between the outer cuff folded edge 75 and the outer cuff material
edge 76 and 2) the web of material between the outer cuff folded
edge 75 and the inner cuff folded edge 72; wherein in at least a
portion of the second waist region, the outer cuff is free of
elastics adhesive 79 and elastic members 77, thus forming a leg
gasketing system pocket 47 between 1) the web of material between
the outer cuff folded edge 75 and the outer cuff material edge 76
and 2) the web of material between the outer cuff folded edge 75
and the inner cuff folded edge 72, the leg gasketing system pocket
47 having an outboard longitudinal edge 49 at the outer cuff folded
edge 75; wherein the leg gasketing system pocket 47 comprises an
opening 51 on an inboard longitudinal edge 48 of the leg gasketing
system pocket.
The pocket 47 may include a thermal or compression bond that
defines at least a portion of the perimeter of the pocket (e.g.,
the entire perimeter of the pocket), such that the at least a
portion of the pocket 47 (e.g., the entire pocket), can be made
visible to a wearer or caregiver as to signal the functionality of
the pocket 47 prior to use.
The pocket 47 may extend to the lateral edge of the chassis and
create channels for facilitating the flow of runny bowel movement.
This open channel area can be sealed by any suitable bonding
technique such as glue, mechanical bonds, thermal bonds, or the
like.
The hydrophobic properties, such as Low Surface Tension
Strikethrough or Hydro Head, can be increased in a least a portion
of the pocket 47, in such a way that prevents exudates from leaking
through the materials that comprise the pocket. Accordingly, this
will maintain separation of the contained fecal material from the
wearer. Increasing hydrophobic properties can be accomplished by
applying hydrophobic coatings, inks, glues, silicones, additional
materials, or any combination thereof, or by any other means known
in the art.
The outer cuff 74 and inner cuff 71 may be the same color. The
outer cuff 74 and inner cuff 71 may be different colors. There may
be an additional printing on one or more of the cuffs of the leg
gasketing system 70. In articles with printing on both the inner
and outer cuffs, the printing may be the same or different on each
cuff.
The leg gasketing system 70 may include a printed zone that
outlines or defines at least a portion of the pocket 47 such that
the benefit can be signaled prior to use.
The outer cuff 74 may comprise elastic members 77 positioned in a
lateral array between the outer cuff folded edge 75 and outer cuff
material edge 76. As illustrated in FIGS. 2-4, the elastics 77, 78
are attached to the portion of the web of material that forms the
outer cuff by elastics adhesive 79. The elastics may be positioned
between 1) the portion of the web of material between the outer
cuff folded edge 75 and the outer cuff material edge 76, and 2) the
portion of the web material between the outer cuff folded edge 75
and the inner cuff folded edge 72. The outer cuff 74 may comprise
at least two elastic members 77, at least three elastic members 77,
at least four elastic members 77, at least five elastic members 77,
or at least six elastic members 77. The elastic members 77 may be
disposed between the outer cuff folded edge 75 and the inner cuff
material edge 73.
The inner cuff 71 may comprise an array of elastic members 78
positioned in a lateral array between the inner cuff folded edge 72
and the inner cuff material edge 73. The elastics attached to the
portion of the web of material that forms the inner cuff by
elastics adhesive 79. The elastics may be positioned between 1) the
portion of the web of material between the inner cuff folded edge
72 and the inner cuff material edge 73, and 2) the portion of the
web material between the inner cuff folded edge 72 and the outer
cuff folded edge 75. The inner cuff 71 may comprise at least one
elastic member 78, at least two elastic members 78, at least three
elastic members 78, at least four elastic members 78, or at least
five elastic members 78. The elastic members 78 may be disposed
between the inner cuff folded edge 72 and the outer cuff material
edge 76.
The outer cuff 74 may comprise at least one more elastic member 77
than the inner cuff 71 elastic member(s) 78. The inner cuff
material edge 73 may be laterally outboard the outer cuff material
edge 76.
The elastic members 77 and 78 may be spaced at least 2 mm apart
from one edge of the member to the other edge of the member,
optionally at least 3 mm apart; optionally at least 3.5 mm apart;
optionally at least 4 mm apart; optionally at least 4.5 mm apart;
optionally at least 5 mm apart; optionally at least 5.5 mm apart;
optionally at least 6 mm apart; optionally at least 6.5 mm apart;
optionally at least 7 mm apart; optionally at least 7.5 mm apart;
optionally at least 8 mm apart; optionally at least 8.5 mm apart;
optionally at least 9 mm apart; optionally at least 9.5 mm apart;
optionally at least 10 mm apart; optionally at least 10.5 mm apart;
optionally at least 11 mm apart; optionally at least 11.5 mm apart;
optionally at least 12 mm apart. The outermost elastic members 77
and 78 may be less than about 2 mm from the outer cuff material
edge 76 and inner cuff material edge 73; optionally less than about
1.5 mm, less than about 1 mm.
The outer cuff 74 may have four elastic members 77 that are about 4
mm apart. The outer cuff 74 may have four elastic members that are
about 2 mm/7 mm/2 mm apart. The outer cuff 74 may have three
elastic members 77 that are about 6 mm apart. The outer cuff 74 may
have two elastic members that are about 12 mm apart. The outer cuff
74 may have four elastic members that are about 3 mm/6 mm/3 mm
apart, as spaced from the outer cuff folded edge 75. The elastic
members may be about 2 mm from the outer cuff folded edge 75,
optionally about 0 mm from the outer cuff folded edge 75.
The leg gasketing system 70 may have an inner cuff 71 comprised of
an inner cuff folded edge 72 and an inner cuff material edge 73.
The leg gasketing system 70 may further comprise an outer cuff 74
comprising an outer cuff folded edge 75 and an outer cuff material
edge 76. The leg gasketing system may comprise a first material
comprising the inner cuff 71 and a second material comprising the
outer cuff 74. The first and second material may overlap and be
joined together along a longitudinal edge of each material by any
suitable bonding means (i.e., a single web), or be separate webs of
material. The web of material may be folded laterally inward to
form the outer cuff folded edge 75 and folded laterally outward to
form the inner cuff folded edge 72. The proximal edges of the outer
cuff 74 may be coterminous. The proximal edges of the outer cuff 74
may be spaced greater than about 2 mm apart; greater than about 4
mm; greater than about 6 mm; greater than about 10 mm apart. The
proximal material edges of the cuff may be both bonded to the inner
cuff. Only one of the proximal material edges of the outer cuff 74
may be bonded to the inner cuff. The proximal material edges of the
outer cuff are held together with any suitable bonding means.
The leg gasketing system 70 may be spaced laterally inward of the
chassis longitudinal edge 12 by about 10 mm, optionally about 20
mm, optionally about 30 mm, optionally about 60 mm or more. The
laterally outboard edge of the chassis may be defined by the
lateral edge of the outer cuff. The backsheet and/or polymeric film
may be spaced laterally inward of the outer cuff edge by about 10
mm; optionally about 20 mm; optionally about 30 mm; optionally
about 40 mm.
The laterally outboard edge of the leg gasketing system 70 may be
disposed laterally inboard of at least a portion of the
longitudinal edge of the article in at least one of the waist
regions. Thus, the front ears 40 and/or back ears 42 may extend
past the leg gasketing system 70.
The height of the inner cuff 71 may be at least about 10 mm, at
least about 20 mm, a least about 30 mm, at least about 32 mm, at
least about 35 mm, at least about 38 mm. The height of the outer
cuff 74 may be at least about 15 mm, at least about 23 mm, at least
about 25 mm, at least about 27 mm, at least about 30 mm. The height
of the inner cuff is measured from inner cuff folded edge 72 to the
first point of connection to a material beyond the inner cuff
material edge 73 in the crotch region. The outer cuff height is
measured from the outer cuff folded edge 75 to the first point of
connection the inner cuff 72 has to a material beyond the inner
cuff material edge 73 in the crotch region. Thus, the inner and
outer cuffs are measured from their respective folded edges to the
point where the inner cuff is connected to the first material
beyond the inner cuff material edge.
One advantage of the leg gasketing system 70 detailed herein is
that when a substantially liquid-impervious material is used in
construction of the cuff, the polymeric film layer may be narrowed
or not present at all, resulting in more cost effective designs.
Utilizing adhesive technologies that are more reliably processed
results in more reliable performance and creates substantially
liquid impervious seals. This technology enables narrowing the film
layer to be only slightly wider than the absorbent core by reducing
the need for redundant seals.
The backsheet polymeric film may be less than about 50 mm wider
than the absorbent core; optionally less than about 40 mm wider,
less than about 30 mm wider. The backsheet polymeric film may be at
least about 20 mm more narrow than the chassis width; optionally at
least about 40 mm more narrow than the chassis width; optionally at
least about 60 mm more narrow than the chassis width; optionally at
least about 80 mm more narrow than the chassis width; optionally at
least about 100 mm more narrow than the chassis width; optionally
at least about 120 mm more narrow than the chassis width.
The leg cuff may be joined to the topsheet and/or backsheet by a
slot coated adhesive. At least about 12 gsm of adhesive may be
applied; optionally at least about 15 gsm of adhesive is applied;
optionally at least about 20 gsm of adhesive is applied;
optionally, at least about 25 gsm of adhesive is applied;
optionally at least about 40 gsm of adhesive is applied; optionally
at least about 60 gsm of adhesive is applied. The adhesive may be
at least about 1 mm wide; optionally at least about 3 mm wide;
optionally at least about 7 mm wide. The adhesive may be at least
about 2 mm inboard of the outboard lateral edge of the film;
optionally at least 4 mm inboard of the outboard lateral edge of
the film; optionally at least about 6 mm inboard of the outboard
lateral edge of the film. The leg cuff may be joined to the
topsheet and/or backsheet by two overlapping and redundant spiral
adhesive sprays; optionally three overlapping and redundant spiral
adhesive sprays.
The descriptions of the invention including the pocket 47 and
opening 51 that allow for trapping exudates can be used in
conjunction with an article that does not contain an absorbent
core. This is useful for a product that is designed to be used in
the medical industry as it can enable the collection of exudates
for analysis easier without the exudates being absorbed into the
product.
Additional exemplary leg gasketing systems 70 that may be useful in
the absorbent articles detailed herein are shown in FIGS. 11a-11t
of the accompanying drawings.
Waist Gasketing Element:
The disposable absorbent article 20 may include at least one waist
gasketing element 81 that is attached to both the chassis 22 and
the leg gasketing system 70. FIG. 12 is a schematic view of the
disposable absorbent article 20 as detailed herein that includes a
waist gasketing element 81 in the second waist region 38. FIG. 13
is a close-up schematic view of the second waist region 38 of FIG.
12. FIG. 14 depicts a schematic cross sectional view of the
exemplary second waist region 38 of FIG. 13 in a flat, uncontracted
state, the view taken through the longitudinal centerline 100.
FIGS. 15-18 also depict schematic cross sectional views of the
second waist region 38 of FIG. 13. FIGS. 15 and 17 are schematic
cross sectional views through line D-D of FIG. 13. FIGS. 16 and 18
are schematic cross sectional views through line E-E of FIG.
13.
The at least one waist gasketing element 81 may comprise a single,
continuous web of material. An absorbent article having a single
web of material may provide a cost advantage over absorbent
articles having more than one web of material. Further, a waist
gasketing element formed from one web of material may have fewer
leaks, as there are no holes created by bonding more than one web
of material. Also, an absorbent article having one web of material
may be more aesthetically pleasing, as fewer bonds are visible. The
waist gasketing element(s) 81 may be formed from more than one web
of material (e.g., multiple webs of material that are joined
together to become one web of material, or multiple distinct webs
of material that are separate from the disposable absorbent article
chassis and form part of the waist gasketing element). Herein,
locations (e.g., folded edge, material edge, etc.) on the waist
gasketing element 81 are detailed in reference to "a web of
material" or "a portion of the web of material." The recitations of
"a web of material" or "the web of material" refer to waist
gasketing elements that may be formed from a single, continuous web
of material, multiple webs of material that are joined together to
become one web of material, a single material that is folded to
form multiple layers of the same material, a single material that
is slit apart and rejoined together, or multiple distinct webs of
material that are separate from the disposable absorbent article
chassis and form part of the leg gasketing system. All such
absorbent articles are contemplated.
The waist gasketing element 81 may include an inboard lateral edge
82, an outboard lateral edge 83, and two longitudinal edges 84. The
web of material forming the waist gasketing element 81 may be
folded longitudinally outward (away from the lateral centerline 110
of the absorbent article 20) to form the inboard lateral edge 82.
The inboard lateral edge 82 may also be the location of the waist
gasketing element folded edge 89 and the outboard lateral edge 83
is also the location of the waist gasketing element first material
edge 90 and the waist gasketing element second material edge 91.
Although an absorbent article depicting a waist gasketing element
81 with one folded edge 89 and two material edges 90, 91 is shown
in FIGS. 13-18, alternate constructions of useful waist gasketing
elements are contemplated. For example, an alternate waist
gasketing element 81 may include two distinct webs of material and
therefore have four material edges (two on the inboard lateral edge
82, and two on the outboard lateral edge 83). As another example,
an alternate waist gasketing element may have a continuous web
material that is formed into having two folded edges (one on the
inboard lateral edge 82, and one on the outboard lateral edge 83)
and two material edges.
Further, the waist gasketing element 81 is attached to: 1) the
chassis 22 of the disposable absorbent article 20 and 2) the leg
gasketing system 70, such that at least a portion of the outboard
lateral edge 83 of the waist gasketing element 81 is attached to
the chassis 22 and at least a portion of the outboard lateral edge
83 of the waist gasketing element 81 is attached to the web of
material of the leg gasketing system 70; and wherein the inboard
lateral edge 82 of the waist gasketing element 81 is unattached to
the chassis 22 of the disposable absorbent article 20. In absorbent
articles that include a waist gasketing element 81 that have a
waist gasketing element folded edge 89, a waist gasketing element
first material edge 90, and a waist gasketing element second
material edge 91, at least a portion of the web of material between
the waist gasketing element folded edge 89 and waist gasketing
element second material edge 91 is attached to the topsheet 24
and/or backsheet 26 of the chassis 22. The attachment of the waist
gasketing element 81 to the chassis 22 is made through utilization
of one or more outboard lateral edge bonds 85. As seen in the
absorbent article of FIGS. 12-14, the outboard lateral edge bond 85
attaches at least a portion of the waist gasketing element's web of
material between the waist gasketing element folded edge 89 and the
waist gasketing element second material edge 91 to the topsheet 24.
The attachment bond 85 may be at the second waist edge 14 of the
chassis 22; the attachment bond may be placed at least 2 mm inboard
from the waist edge of the chassis; at least 10 mm inboard from the
waist edge of the chassis; at least 20 mm inboard from the waist
edge of the chassis; at least 50 mm inboard from the waist edge of
the chassis; or any range or distance within the range of about 2
mm to about 50 mm inboard from the waist edge of the chassis. The
outboard lateral edge bond 85 may take the form of glue, heat bond,
pressure bond, CPW bonds, or any other bonding method known in the
art. In the absorbent articles of FIGS. 12-14, the outboard lateral
edge bond 85 takes the form of a glue bond, thermal bond or
compression bond.
In absorbent articles that include a waist gasketing element 81
that has a waist gasketing element folded edge 89, a waist
gasketing element first material edge 90, and a waist gasketing
element second material edge 91, at least a portion of the web of
material between the waist gasketing element folded edge 89 and
waist gasketing element second material edge 91 is attached to the
web of material forming the leg gasketing system 70. The attachment
of the waist gasketing element 81 to the web of material forming
the leg gasketing system 70 is made through utilization of one or
more longitudinal edge bond(s) 86. As seen in the absorbent article
of FIGS. 12-18, the longitudinal edge bonds 86 attach at least a
portion of the waist gasketing element's web of material between
the waist gasketing element folded edge 89 and the waist gasketing
element second material edge 91 to the web of material forming the
leg gasketing system 70. In the absorbent article illustrated in
FIGS. 15-16, the longitudinal edge bonds 86 are located adjacent to
the longitudinal edges 84 of the waist gasketing element 81 (or may
be coterminous therewith). In another absorbent article (not
illustrated), the longitudinal edge bonds 86 are located adjacent
to the inner cuff folded edge 72 of the leg gasketing system 70 (or
may be coterminous therewith). In the absorbent article illustrated
in FIGS. 17-18, the longitudinal edge bonds 86 are wider than in
the absorbent article of FIGS. 15-16, and span the distance between
1) the longitudinal edges 84 of the waist gasketing element 81 and
2) the inner cuff folded edge 72 of the leg gasketing system 70. In
other words, specifically regarding the longitudinal edge bonds 86
for the absorbent article shown in FIGS. 17-18, the waist gasketing
element 81 is attached to the leg gasketing system 70 over
substantially the entire area that the leg gasketing system 70
overlaps with the waist gasketing element 81. The waist gasketing
element 81 may be attached to the leg gasketing system 70 over more
than about 50%, more than about 60%, more than about 70%, more than
about 80%, more than about 90%, or more than about 95%, of the
entire area that the leg gasketing system 70 overlaps with the
waist gasketing element 81. The longitudinal edge bonds 86 may take
the form of glue, heat bond, pressure bond, CPW bonds, or any other
bonding method known in the art. In the absorbent articles of FIGS.
12-18, the longitudinal edge bonds 86 take the form of a glue bond,
thermal bond or compression bond.
The portion of the web material between the waist gasketing element
folded edge 89 and the waist gasketing element first material edge
90 may be attached to the portion of the web material between the
waist gasketing element folded edge 89 and the waist gasketing
element second material edge 91 by at least one waist gasketing
element bond 92. In the absorbent article illustrated in FIGS.
12-14, the waist gasketing element bond 92 is located adjacent to
the waist gasketing element first material edge 90 and the waist
gasketing element second material edge 91 (waist gasketing element
bond 92 may also be coterminous with the waist gasketing element
second material edge 91). The waist gasketing element bond 92 may
take the form of glue, heat bond, pressure bond, CPW bonds, or any
other bonding method known in the art. In the absorbent articles of
FIGS. 12-14, the waist gasketing element bond 92 takes the form of
a glue bond.
As illustrated in FIGS. 12-18, the inboard lateral edge 82 of the
waist gasketing element 81 is unattached to the chassis 22 of the
disposable absorbent article 20. Due to the waist gasketing element
81 being unattached to the chassis 22, a waist gasketing element
pocket 93 is formed. The waist gasketing element pocket 93 is
illustrated in FIG. 14. The waist gasketing element pocket 93
includes an inboard lateral edge 94 and an outboard lateral edge
95, which define the longitudinal length dimension of the waist
gasketing element pocket 93. The inboard lateral edge 94 of the
waist gasketing element pocket 93 may be coterminous with the waist
gasketing element folded edge 89. The outboard lateral edge 95 of
the waist gasketing element pocket 93 may be coterminous with the
outboard lateral edge bond 85. The outboard lateral edge 95 may be
coterminous with the most outboard bond of the waist gasketing
element 81. The waist gasketing element pocket 93 includes an
opening 96 which runs a distance along the inboard lateral edge 94
of the waist gasketing element pocket 93.
For the absorbent article shown in FIG. 13, the overall
longitudinal length of the waist gasketing element pocket 93 is the
distance from the waist gasketing element folded edge 89 of the
waist gasketing element pocket to the outboard lateral edge bond
85. In other words, for the absorbent article shown in FIG. 13, the
longitudinal dimensions of the waist gasketing element pocket 93
are defined by the waist gasketing element folded edge 89 and the
outboard lateral edge bond 85. The overall longitudinal length of
the waist gasketing element pocket 93 may measure between about 5
mm and about 100 mm in the longitudinal direction, or any range or
distance within the range of about 5 mm to about 100 mm; in some
absorbent articles, about 60 mm, about 40 mm, or about 35 mm; and
in other absorbent articles the overall longitudinal length
measures between about 1 mm and about 30 mm.
For the absorbent article shown in FIG. 13, the overall lateral
width of the waist gasketing element 81 is the distance from the
longitudinal edge 84 of one side of the waist gasketing element 81
to the longitudinal edge 84 of the other side of the waist
gasketing element. The overall lateral width of the waist gasketing
element 81 may measure between about 60 mm and about 200 mm in the
lateral direction, or any range or distance within the range of
about 60 mm to about 200 mm; in some absorbent articles, about 60
mm, about 100 mm, or about 150 mm; and in other absorbent articles
the overall lateral width measures between about 50 mm and about
300 mm.
Babies, in particular breast fed babies, often have issues with
runny bowel movement ("BM") leaking out of the sides and/or back of
their diapers. Moreover, an absorbent article user of any age may
have an issue from time to time with runny BM leaks. When a wearer
of an absorbent article has a runny bowel movement, many times the
runny bowel movement spreads upon defecation and leaks out of the
absorbent article in an area between the waist region and the
wearer's back. These events are generally referred to as
"blowouts." Blowouts happen because the snug fit between user's
body and the attached absorbent article do not allow enough room
for the runny bowel movement to remain contained within the
absorbent article during the wearer's movement. One advantage of
the waist gasketing element 81 detailed herein, alone or in
combination with the leg gasketing systems as detailed herein, are
the additional pocketed areas (47 and 93) that provide extra void
volumes within the leg cuffs and waist region for containment of
bodily extrudate (e.g., fecal material). When the wearer moves, a
portion of the bodily extrudate will migrate into the waist
gasketing element pocket 93 for containment and be held/trapped
between two layers of nonwoven before it can leak out in an area
between the wearer's back and the back waist region of the
absorbent article. Thus, the waist gasketing element 81 detailed
herein reduces leaks. Moreover, the waist gasketing element pocket
93 provides additional void volume within the waist region to
receive the fecal material which helps in isolating the fecal
material from wearer's skin.
Further, the waist gasketing element pocket 93 may work in
conjunction with the leg gasketing system pocket 47 to provide even
more void volume within the absorbent article to receive fecal
material and/or provide an easier path for fecal material to find
the leg gasketing system pocket opening 51. The gasketing action of
any elastic material (e.g., leg elastics 87, detailed below) within
the waist gasketing element 81 may function to lift the inboard
lateral edge 82 of the waist gasketing element 81 away from the
chassis 22 of the absorbent article. The longitudinal edge bonds 86
of the waist gasketing element 81 attach the waist gasketing
element to the inner cuff 71 and/or the outer cuff 74 of the leg
gasketing system 70. Accordingly, the gasketing action of any
elastic material (e.g., leg elastics 87) within the waist gasketing
element 81 may also function to lift the inner cuff 71 and/or outer
cuff 74 of the leg gasketing system 70 away from the chassis 22,
therefore amplifying the opening 51 of the leg gasketing system
pocket 47. With the opening 51 of the leg gasketing system pocket
47 opened up, the pocket can more readily accept fecal material
such as runny bowel movement.
As detailed above, the leg gasketing system 70 and/or the waist
gasketing element 81 and/or a combination of both as described
herein may assist in reducing runny BM leaks/blowouts. The Blowout
Method Test, as defined herein, was developed to quantify how
efficient an absorbent article (e.g., a diaper) is at containing
runny BM, thus avoiding blowouts.
The combination of the waist gasketing element pocket 93 and the
leg gasketing system pocket 47 provides more void volume within the
absorbent article that helps in containing more fecal material.
Particularly for the waist gasketing element 81, the overall
longitudinal length of the waist gasketing element pocket 93
multiplied by the overall lateral width of the waist gasketing
element pocket (multiplied by the amount the waist gasketing
element 81 is spaced away from the chassis 22) define the active
void volume under the waist gasketing element 81. In the situation
of BM blowouts, this active void volume under the waist gasketing
element 93 provides more area for BM containment, thus minimizing
and/or avoiding blowouts.
This active void volume under waist gasketing element 93 also
relates to the size of the absorbent article and the amount/volume
of BM it can contain. For larger size absorbent articles, and thus
larger users, higher active void volume is required to contain more
fecal material and avoid blowouts. This can be achieved by
increasing the overall longitudinal length of the waist gasketing
element pocket 93 and overall lateral width of the waist gasketing
element pocket. Therefore for the Blowout Method Test, as defined
herein, larger quantities of artificial BM and saline are required
for larger sized absorbent articles.
TABLE-US-00001 TABLE 1 Blowout Method Test Results Blowout Blowout
Diaper Total Total Saline Leakage Percent Efficiency Factor =
Weight Artificial BM Volume Weight Leakage (Blowout Leakage (Avg.)
Weight added added (Avg.) (Avg.) Weight/Diaper Product grams grams
ml grams % Weight) * 100 Prototype 25.5 100 100 4.91 4.91% 19.3
Absorbent Article, Size 2* 2015 Pampers 22.58 100 100 18.07 18.07%
80.0 Swaddlers, Size 2 2015 Huggies 24.89 100 100 15.30 15.30% 61.5
Snug and Dry, Size 2 Huggies Korean 35.3 150 150 14.29 9.53% 40.5
L, Size 4** 2015 Pampers 31.47 150 150 25.61 17.07% 81.4 Swaddlers,
Size 4 2015 Pampers 33.35 150 150 24.60 16.40% 73.8 Swaddlers, Size
5 *The Prototype Absorbent Article tested for the data generation
tabulated in Table 1 was an absorbent article with a structure as
shown in FIGS. 12-16. The overall longitudinal length of the waist
gasketing element pocket 93 of the Prototype Absorbent Article was
34 mm and the overall lateral width of the waist gasketing element
pocket was 140 mm. The overall lateral width of the leg gasketing
system pocket 47 in the Prototype Absorbent Article was 20 mm.
**The Huggies, Korea L, Size 4 product was made by Kimberly Clark
and sold in Korea in 2015. The packaging lot number is
20140725TJ04271440725.
After being tested by the Blowout Method Test as described herein,
the absorbent articles described herein may have a Blowout Percent
Leakage of less than about 9.0%, less than about 8.0%, less than
about 7.0%, less than about 6.0%, less than about 5.0%, less than
about 4.0%, less than about 3.0%, less than about 2.0%, or less
than about 1.0%, or any range of Blowout Percent Leakage within the
previous ranges. The absorbent articles described herein may have a
Blowout Percent Leakage of between about 0.1% and about 9.0%,
between 1.0% and about 9.0%, between about 2.0% and about 9.0%,
between about 3.0% and about 9.0%, between about 4.0% and about
9.0%, between about 5.0% and about 9.0%, or any range of Blowout
Percent Leakage within such ranges.
After being tested by the Blowout Method Test as described herein,
the absorbent articles described herein may have a Efficiency
Factor=(Blowout Leakage Weight/Diaper Weight)*100 of less than
about 40.0, less than about 35.0, less than about 30.0, less than
about 25.0, less than about 20.0, less than about 15.0, less than
about 10.0, less than about 5.0, or less than about 2.0, or any
range of Efficiency Factor within the previous ranges. The
absorbent articles described herein may have an Efficiency Factor
of between about 0.1 and about 40.0, between 5.0 and about 35.0,
between about 10.0 and about 35.0, between about 15.0 and about
35.0 between about 20.0 and about 35.0, between about 20.0 and
about 30.0, between about 0.1 and about 25.0, or any range of
Efficiency Factor within such ranges. Absorbent articles with lower
values for Efficiency Factor indicate a balance of high prevention
of blowouts, while also using less diaper materials (the diaper
weighs less and therefore uses less material). Accordingly, the
absorbent articles described herein are better performing in
preventing runny BM blowouts, while costing less and having less
environmental impact (i.e., having better economic efficiency and
environmental efficiency).
The prototype absorbent article tested, and the data reflected in
Table 1 above, weighed under 30.0 g and therefore 100.0 ml of
saline (two separate 50.0 ml applications) and 100.0 g of
artificial BM was used for testing. The prototype absorbent article
included the leg gasketing system 70 and the waist gasketing
element 81 which comprise N-fiber material. The combination of
waist gasketing element pocket 93 and leg gasketing system pocket
47 provides more void volume within the prototype absorbent article
that assists in reducing Blowout Percent Leakage. Particularly for
the waist gasketing element 81, the overall longitudinal length of
the waist gasketing element pocket 93 tested was 34 mm and the
overall lateral width of the waist gasketing element pocket tested
was 140 mm. The overall lateral width of the leg gasketing system
pocket 47 in the prototype absorbent article was 20 mm. This active
void volume under waist gasketing element 93 can be increased by
increasing overall longitudinal length of the waist gasketing
element pocket 93 and overall lateral width of the waist gasketing
element pocket. Therefore, for other prototype absorbent articles
as described herein with higher active void volume waist gasketing
element designs, the Blowout Percent Leakage will be further
reduced (and therefore further avoid BM blowouts) when tested under
the Blowout Method Test.
While not being bound by theory, it is believed that the waist
gasketing element 81 can provide a seal to the body which is
created by multiple aspects of the invention. First, the waist
gasketing element 81 is elasticated and designed to be under
tension in use. The tension in use is created by the caregiver in
the process of applying the product as she/he is trying to achieve
a snug fit. Through the Capstan effect, the tension created during
application and the radius of the body provides a force between the
waist gasketing element and the body which is in the normal
direction with respect to the body. This normal force between the
waist gasketing element 81 and the body provides the initial seal
that causes bodily extrudate to run between the waist gasketing
element 81 and the chassis or topsheet, and causes the bodily
extrudate to be forced into the waist gasketing element pocket 93.
Furthermore, it is known that rapidly excreted bodily extrudate has
a pressure which causes the distribution of the bodily extrudate
throughout the absorbent article 20. If the bodily extrudate is
trapped between the waist gasketing element 81 and the chassis 22,
then the pressure created from the bodily extrudate will act to
further seal the waist gasketing element 81 against the body,
adding to the normal force created by the aforementioned Capstan
effect and creating an even better seal. Since the waist gasketing
element 81 is sealed to the body, bodily extrudate can't escape and
then an amount of the bodily extrudate is forced laterally sideways
into the leg gasketing system pocket 47 for storage.
To achieve the maximum effectiveness from the Capstan effect, which
leads to the sealing of the waist gasketing element 81 to the body,
the leg gasketing system should ideally be positioned in an area of
the body which has a continuous convex surface or a continuous
cylindrical shape or approximation thereof. If the body surface
becomes concave or "valley-like" at any point, the waist gasketing
element 81 will not be able to form a proper seal between the body
and the waist gasketing element. This will allow exudates to escape
through the space between the body and the waist gasketing element
81. Therefore, it important to position the waist gasketing element
81 above the gluteal groove, in such a way as to ensure that the
body has the right geometry to enable the seal to be adequately
formed. Ideally, the waist gasketing element 81 can be positioned
at the top of the gluteal groove, 10 mm above the gluteal grove, 25
mm above the gluteal groove, or 50 mm above the gluteal groove.
In addition, it may be useful to make the waist gasketing element
81 tall enough so that if the chassis 22 does not fit close to the
body, the waist gasketing element can still remain in contact.
Additionally, it may be useful to provide enough void volume in the
waist gasketing element pocket 93 such that sufficient amounts of
bodily extrudate can reside there. To ensure that the waist
gasketing element 81 is sufficiently above the gluteal groove and
also is tall enough to seal to the body and create enough void
volume, it is advantageous to position the waist gasketing element
at the top of the absorbent article 20, near or coincident to the
waist edge 13, 14, or as close as possible to the waist edge. With
variability in the placement of the materials in high speed diaper
making applications, it may be necessary to position the waist
gasketing element 81 in such a way as to enable it to be cut apart
as a part of the manufacturing process such that a portion of the
waist gasketing element 81 is attached to a first absorbent article
and the remainder is attached to the next absorbent article in the
manufacturing process. This ensures that the top edge of the waist
gasketing element 81 is coterminous to the waist edge 13, 14. Thus,
the waist gasketing element 81 is not spaced down from the waist
edge of the absorbent article. The outboard lateral edge 83 of the
waist gasketing element 81 may be placed 5 mm inboard of the second
waist edge 14 of chassis 22; whereas in some absorbent articles,
the outboard lateral edge 83 of the waist gasketing element is
placed at least 10 mm inboard from the waist edge 13, 14 of the
chassis 22; at least 20 mm inboard from the waist edge of the
chassis; at least 50 mm inboard from the waist edge of the chassis;
or any range or distance within the range of about 2 mm to about
100 mm inboard from the waist edge of the chassis.
The waist gasketing element pocket 93 may include a thermal or
compression bond that defines at least a portion of the perimeter
of the pocket (e.g., the entire perimeter of the pocket), such that
the at least a portion of the pocket 93 (e.g., the entire pocket),
can be made visible to a wearer or caregiver as to signal the
functionality of the pocket 93 prior to use.
Alternately, the waist gasketing element pocket 93 may include a
glue or bond that defines at least a portion of the perimeter of
the pocket (e.g., the entire perimeter of the pocket), such that
the at least a portion of the pocket 93 (e.g., the entire pocket),
can be made visible to a wearer or caregiver as to signal the
functionality of the pocket 93 prior to use.
Alternately, the hydrophobic properties, such as Low Surface
Tension Strikethrough or Hydro Head, can be increased in a least a
portion of the waist gasketing element 81, or in the whole waist
gasketing element, in such a way that prevents exudates from
leaking through the materials that comprise the waist gasketing
element. Accordingly, this will maintain separation of the
contained fecal material from the wearer. Increasing hydrophobic
properties can be accomplished by applying hydrophobic coatings,
inks, glues, silicones, additional materials, or any combination
thereof, or by any other means known in the art. Additionally, it
may be advantageous to include an N-fiber material in the waist
gasketing element to provide the similar benefits as associated
with the leg cuff, as detailed herein.
The waist gasketing element 81 and the leg gasketing system 70 may
be the same color. The waist gasketing element 81 and the leg
gasketing system 70 may be different colors. There may be an
additional printing on the waist gasketing element 81.
The waist gasketing element 81 may include a printed zone that
outlines or defines at least a portion of the waist gasketing
element pocket 93 such that the benefit can be signaled prior to
use. The waist gasketing element 81 may include elastic members 87
positioned in a longitudinal array between the inboard lateral edge
82 and the outboard lateral edge 83 of waist gasketing element 81.
As illustrated in FIG. 14, the elastics 87 are attached to the
portion of the web of material that forms the waist gasketing
element 81 by elastics adhesive 88. In such an absorbent article,
the elastics are positioned between 1) the portion of the web of
material between the waist gasketing element folded edge 89 and the
waist gasketing element first material edge 90, and 2) the portion
of the web material between the waist gasketing element folded edge
89 and the waist gasketing element second material edge 91. The
waist gasketing element 81 may comprise at least two elastic
members 87, at least three elastic members 87, at least four
elastic members 87, at least five elastic members 87, at least six
elastic members 87, at least seven elastic members 87, at least
eight elastic members 87, at least nine elastic members 87, at
least ten elastic members 87, at least eleven elastic members, or
at least twelve elastic members 87.
The elastic members 87 may be spaced at least 2 mm apart from one
edge of the member to the other edge of the member, optionally at
least 3 mm apart; optionally at least 3.5 mm apart; optionally at
least 4 mm apart; optionally at least 4.5 mm apart; optionally at
least 5 mm apart; optionally at least 5.5 mm apart; optionally at
least 6 mm apart; optionally at least 6.5 mm apart; optionally at
least 7 mm apart; optionally at least 7.5 mm apart; optionally at
least 8 mm apart; optionally at least 8.5 mm apart; optionally at
least 9 mm apart; optionally at least 9.5 mm apart; optionally at
least 10 mm apart; optionally at least 10.5 mm apart; optionally at
least 11 mm apart; optionally at least 11.5 mm apart; optionally at
least 12 mm apart. The most inboard elastic members 87 may be less
than about 2 mm from the waist gasketing element folded edge 89;
optionally less than about 1.5 mm, less than about 1 mm. The most
outboard elastic members 87 may be less than about 2 mm from the
outboard lateral edge 83; optionally less than about 1.5 mm, less
than about 1 mm.
The waist gasketing element 81 may have four elastic members 87
that are each about 4 mm apart. The waist gasketing element 81 may
have four elastic members that are about 2 mm/7 mm/2 mm apart. The
waist gasketing element 81 may have five elastic members that are
about 6.5 mm/7.5 mm/9 mm/11 mm apart. The waist gasketing element
81 may have three elastic members 77 that are each about 6 mm
apart. The waist gasketing element 81 may have two elastic members
that are about 12 mm apart. The waist gasketing element 81 may have
four elastic members that are about 3 mm/6 mm/10 mm/20 mm/30 mm
spaced from the inboard lateral edge 82. The elastic members may be
about 2 mm from the inboard lateral edge 82, or about 0 mm from the
outer inboard lateral edge 82 (or be disposed directly adjacent the
inboard folded edge 89).
The elastic members 87 may have a prestrain level of at least 50%;
optionally at least 95%; optionally at least 150%; optionally at
least 200%; optionally at least 250%; optionally at least 300%;
optionally at least 350%; or any range distance within the range of
about 50% to about 350%. The prestrain level is the amount of
strain put on the elastics before the elastic is glued down with
elastics adhesive to the waist gasketing element 81 web of
material. The prestrain level of each elastic member 87 can be
identical, in other absorbent articles, the prestrain levels can be
different from elastic to elastic. The prestrain of elastic
member(s) proximate the inboard lateral edge 82 can be higher than
the prestrain level of the elastic member(s) proximate the outboard
lateral edge 90. In this absorbent article, the contraction level
of the inboard lateral edge 82 may be greater than the contraction
level of the outboard lateral edge 90.
The waist gasketing element 81 may have ability to elongate in
lateral direction from its relaxed state by at least 15 mm, by 35
mm, 40 mm, 50 mm, 60 mm, 70 mm, 80 mm, or even up to 100 mm; or any
range or distance within the range of about 15 mm to about 100
mm.
The decitex (g/mm) type can be different from elastic to elastic in
the waist gasketing element 81. The decitex (g/mm) of elastic
member(s) proximate the inboard lateral edge 82 can be higher than
the decitex (g/mm) of the elastic member(s) proximate the outboard
lateral edge 90. In this absorbent article the contractive forces
proximate to the lateral inboard edge 82 may be higher than the
contractive forces in the lateral outboard edge 90.
The waist gasketing element 81 may be attached to the chassis 22
and the leg gasketing system 70 when the elastics 87 of the waist
gasketing element are only partially extended, but the chassis of
the absorbent article 20 is fully extended. In addition, the waist
gasketing element 81 may be fully extended when the corresponding
waist region is fully extended in the lateral direction. The waist
gasketing element may not be fully extended when the corresponding
waist region is fully extended. In other words, in some absorbent
articles, at least some gathers in the web material of the waist
gasketing element 81 are still present when attaching the waist
gasketing element 81 to the chassis 22 and the leg gasketing system
70, while the materials of the chassis are fully extended. Once
attached, the elastics 87 of the waist gasketing element 81 may
retract from their state of partial extension to a relaxed state.
Attaching the waist gasketing element 81 to the chassis 22 in this
way allows the waist gasketing element 81 to be only partially
extended when the waist region of the absorbent article is fully
extended in use. In other words, in some absorbent articles, when a
user fully extends the waist region of the disposable absorbent
article 20, at least some gathers in the web material of the waist
gasketing element 81 are still present.
Although the waist gasketing element 81 described herein has be
only specifically detailed as being located in the second waist
region 38, in some absorbent articles the waist gasketing element
may be present in the first waist region 36. A waist gasketing
element 81 as detailed herein may be included in both the first
waist region 36 and the second waist region 38. For instance, a
wearer who sleeps on their belly (front) may benefit from the waist
gasketing element 81 being located in the front waist region 36, as
to stop urine leakage out of the front waist during sleep. As with
the waist gasketing element located in the rear waist region, a
waist gasketing element in the front waist region (i.e., first
waist region 36) can also work in conjunction with a leg gasketing
system pocket for the storage of urine as needed to prevent leakage
out of the front of the product.
Opacity Strengthening Patch:
An opacity strengthening patch 80 may be included as part of the
chassis 22. The opacity strengthening patch 80 is an additional
layer of material. The opacity strengthening patch 80 may be
connected to the leg gasketing system 70, the polymeric film layer,
or the backsheet 26. The opacity strengthening patch 80 may be
disposed between the backsheet 26 and leg gasketing system 70 in
either the first waist region 36, the second waist region 38, or
both the first waist region 36 and the second waist region 38 of
the article; the opacity strengthening patch 80 may overlap at
least one of the leg gasketing system 70 and/or the polymeric film
layer (i.e., inner layer of the backsheet 26). The opacity
strengthening patch 80 may be attached to one or both of the leg
gasketing system 70 or the polymer film layer using any suitable
means such as glue, mechanical bonds, thermal bonds, or the like,
so that loads generated during the application process or during
wear can be transferred from the lateral edge of the article to the
leg gasketing system 70 and/or the polymeric film layer. The
opacity strengthening patch is useful in providing the strength
needed to prevent the article from extending excessively during
application and wearing; it also may provide opacity at the sides
and waist to prevent the skin of the user from showing through the
article. Thus, the patch 80 may be located at any portion of the
chassis 22 where strength and opacity is desirable. Materials
suitable to act as the opacity strengthening patch include
materials having a basis weight of at least about 10 gsm, at least
about 15 gsm, at least about 25 gsm. An opacity strengthening patch
useful herein may exhibit the following tensile properties in the
cross direction: at 2% engineering strain for a 1 inch wide sample,
0.4N; at 5% engineering strain for a 1 inch wide sample, 1.25N; at
10% engineering strain for a 1 inch wide sample, 2.5N. One opacity
strengthening patch useful herein is available from Pegas, Znojmo,
CZ, as supplier number 803968.
The opacity strengthening patch 80 may be discrete and is located
in the front and back waist regions of the article. The opacity
strengthening patch may be about 70 mm long in the front,
optionally about 90 mm long in the front; optionally about 120 mm
long in the front. The opacity strengthening patch may be about 70
mm long in the back, optionally about 100 mm long in the back,
optionally about 140 mm long in the back. The opacity strengthening
patch may be continuous and spans the entire length of the
product.
The opacity strengthening patch may have a hunter color opacity of
greater than about 15%, optionally greater than about 25%,
optionally greater than about 40%, optionally greater than 60%.
The opacity strengthening patch may be laterally outboard of the
polymeric film layer. The opacity strengthening patch may overlap
the polymeric film layer in the lateral direction such that it can
be affixed to the polymeric film in order to transmit laterally
directed application and wearing forces from the opacity
strengthening patch to the polymeric film layer. Any suitable
bonding means known in the art may be used to affix the opacity
strengthening patch to the polymeric film layer. The opacity
strengthening patch may overlap the polymeric film layer by about 5
mm, optionally about 10 mm, optionally about 15 mm, optionally
about 20 mm, optionally less than about 30 mm.
There may be a lateral gap between the opacity strengthening patch
and the polymeric film layer and the opacity strengthening patch is
affixed by any suitable bonding means to the leg gasketing system,
and the leg gasketing system is affixed to the polymeric film layer
by any suitable bonding means such that application and wearing
loads can transmit from the opacity strengthening patch to the
gasketing system and then from the gasketing system to the
polymeric film layer. The gap may preferably be less than 30 mm,
more preferably less than 20 mm, more preferably less than 10
mm.
There may be a lateral gap between the opacity strengthening patch
and the polymeric film layer; the opacity strengthening patch may
be affixed by any suitable bonding means to the leg gasketing
system and the body facing and garment facing sides of the leg
gasketing system may be affixed together by any suitable bonding
means so that the loads from the opacity strengthening patch are
shared by both layers of the leg gasketing system. The leg
gasketing system may be affixed to the polymeric film layer by any
suitable bonding means such that application and wearing loads can
transmit from the opacity strengthening patch to the leg gasketing
system and then from the leg gasketing system to the polymeric film
layer.
The opacity strengthening patch may overlap the leg gasketing
system in the lateral direction such that it can be affixed
securely to the opacity strengthening patch layer by any suitable
bonding means as a way to transmit application and wearing forces
from the opacity strengthening patch to the leg gasketing system.
The opacity strengthening patch may overlap the leg gasketing
system by about 5 mm, optionally about 10 mm, optionally less than
about 15 mm, optionally less than about 25 mm.
The leg gasketing system may have about the same lateral tensile
strength properties as the opacity strengthening patch. The
combined properties of the leg gasketing system and the backsheet
nonwoven outer cover may have about the same lateral tensile
strength as the opacity strengthening patch. Alternately, the
outercover nonwoven may have very low lateral strength between
about 0% and about 10% engineering strain. The outercover nonwoven
may exhibit the following tensile properties: at 10% engineering
strain for a 1 inch wide sample, 0.4N.
Construction Materials:
It is recognized that there are many combinations of material
lateral tensile properties that could form a substantially suitable
force transmission pathway in the waist region or the article
without excessive lateral stretch in the waist region, and that the
material force pathways may go from the opacity strengthening patch
directly into the polymeric film layer or into the polymeric film
layer through a variety of other layers in the region immediately
outboard the polymeric film layer. These layers may include the
topsheet, backsheet nonwoven, cuff, absorbent assembly, leg
gasketing system, or any other layer that is located in a region
adjacent to the polymeric film layer.
The material of the leg gasketing system 70 may be made from a
substantially liquid impervious material. The material may be
selected from the group consisting of an SMS nonwoven, SMMS
nonwoven material, or a nonwoven component layer comprising
"N-fibers".
Various nonwoven fabric webs may comprise spunbond, meltblown,
spunbond ("SMS") webs comprising outer layers of spunbond
thermoplastics (e.g., polyolefins) and an interior layer of
meltblown thermoplastics. The leg gasketing cuff 70 may comprise a
nonwoven component layer having fine fibers ("N-fibers") with an
average diameter of less than 1 micron (an "N-fiber layer") may be
added to, or otherwise incorporated with, other nonwoven component
layers to form a nonwoven web of material. The N-fiber layer may be
used to produce a SNS nonwoven web or SMNS nonwoven web, for
example.
The leg gasketing cuff 70 may comprise a first nonwoven component
layer comprising fibers having an average diameter in the range of
about 8 microns to about 30 microns, a second nonwoven component
layer comprising fibers having a number-average diameter of less
than about 1 micron, a mass-average diameter of less than about 1.5
microns, and a ratio of the mass-average diameter to the
number-average diameter less than about 2, and a third nonwoven
component layer comprising fibers having an average diameter in the
range of about 8 microns to about 30 microns. The second nonwoven
component layer is disposed intermediate the first nonwoven
component layer and the third nonwoven component layer.
The N-fibers may be comprised of a polymer, e.g., selected from
polyesters, including PET and PBT, polylactic acid (PLA), alkyds,
polyolefins, including polypropylene (PP), polyethylene (PE), and
polybutylene (PB), olefinic copolymers from ethylene and propylene,
elastomeric polymers including thermoplastic polyurethanes (TPU)
and styrenic block-copolymers (linear and radial di- and tri-block
copolymers such as various types of Kraton), polystyrenes,
polyamides, PHA (polyhydroxyalkanoates) and e.g. PHB
(polyhydroxubutyrate), and starch-based compositions including
thermoplastic starch, for example. The above polymers may be used
as homopolymers, copolymers, e.g., copolymers of ethylene and
propylene, blends, and alloys thereof. The N-fiber layer may be
bonded to the other nonwoven component layers by any suitable
bonding technique, such as the calender bond process, for example,
also called thermal point bonding.
The use of an N-fiber layer in a nonwoven web may provide a low
surface tension barrier that is as high as other nonwoven webs that
have been treated with a hydrophobic coating or a hydrophobic
melt-additive, and still maintain a low basis weight (e.g., less
than 15 gsm or, alternatively, less than 13 gsm). The use of the
N-fiber layer may also provide a soft and breathable (i.e., air
permeable) nonwoven material that may be used in single web layer
configurations in applications which previously used double web
layer configurations. Furthermore, the use of the N-fiber layer may
at least reduce the undesirable migration of hydrophilic
surfactants toward the web and, therefore, may ultimately result in
better leak protection for an associated absorbent article. Also,
when compared to an SMS web having a similar basis weight, the use
of a nonwoven web comprising the N-fiber layer may decrease the
number of defects (i.e., holes or pinholes through the mechanical
bond site) created during the mechanical bonding process. N-fibers
are further discussed in WO 2005/095700 and U.S. patent application
Ser. No. 13/024,844.
The inner cuff 71 web of material may have a hydrostatic head of
greater than about 2 mbar, greater than about 3 mbar, greater than
about 4 mbar. The outer cuff 74 web of material may have a
hydrostatic head of less than about 200 mbar, less than about 100
mbar, less than about 75 mbar, less than about 50 mbar, less than
about 25 mbar, less than about 15 mbar.
The folded outer cuff web of material may have a basis weight of 10
gsm; optionally 13 gsm; optionally 15 gsm; optionally 18 gsm.
The inner cuff 71 web of material may have an opacity of from about
15% to about 50% hunter opacity; optionally from about 20% to about
45% hunter opacity. The outer cuff 74 web of material may have an
opacity of from about 45% to about 75% hunter opacity; optionally
from about 50% to about 70% hunter opacity; optionally less than
about 75% hunter opacity; optionally less than about 70% hunter
opacity.
The inner cuff 71 web of material may have an air permeability of
less than about 50 m.sup.3/m.sup.2/min; optionally less than about
45 m.sup.3/m.sup.2/min. The outer cuff 74 web of material may have
an air permeability of greater than about 5 m.sup.3/m.sup.2/min;
optionally greater than about 10 m.sup.3/m.sup.2/min; optionally
greater than about 15 m.sup.3/m.sup.2/min; optionally greater than
about 20 m.sup.3/m.sup.2/min.
The inner cuff 71 web of material may have a WVTR of less than
about 5500 g/m.sup.2/24 hrs; optionally less than about 5400
g/m.sup.2/24 hrs. The outer cuff 74 web of material may have a WVTR
of greater than about 4250 g/m.sup.2/24 hrs; optionally greater
than about 4500 g/m.sup.2/24 hrs; optionally greater than about
5000 g/m.sup.2/24 hrs; optionally greater than about 5250
g/m.sup.2/24 hrs; optionally greater than about 5500 g/m.sup.2/24
hrs.
The gasketing cuffs 70 may be substantially inelastic or may be
elastically extensible to dynamically fit at the wearer's leg. The
gasketing cuff 70 may be formed by one or more elastic members 77
and 78 (such as elastic strands) operatively joined to the topsheet
24, backsheet 26, or any other suitable substrate used in the
formation of the absorbent article 20. Suitable gasketing cuff
construction is further described in U.S. Pat. No. 3,860,003
The inner cuff 71 may span the entire longitudinal length of the
absorbent article 20. The inner cuff 71 may be formed by a flap and
an elastic member 78 (such as elastic strands). The inner cuff 71
may be a continuous extension of any of the existing materials or
elements that form the absorbent article 20.
The inner cuff 71 may comprise a variety of substrates such as
plastic films and woven or nonwoven webs of natural fibers (e.g.,
wood or cotton fibers), synthetic fibers (e.g., polyester or
polypropylene fibers), or a combination of natural and synthetic
fibers. The flap may comprise a nonwoven web such as spunbond webs,
meltblown webs, carded webs, and combinations thereof (e.g.,
spunbond-meltblown composites and variants). Laminates of the
aforementioned substrates may also be used to form the flap. A
particularly suitable flap may comprise a nonwoven available from
BBA Fiberweb, Brentwood, Tenn. as supplier code 30926. A
particularly suitable elastic member is available from Invista,
Wichita, Kans. as supplier code T262P. Further description of
diapers having inner barrier cuffs and suitable construction of
such barrier cuffs may be found in U.S. Pat. Nos. 4,808,178 and
4,909,803. The elastic member 78 may span the longitudinal length
of the inner cuff 71. The elastic member 78 may span at least the
longitudinal length of the inner cuff 71 within the crotch region
37. It is desirable that the elastic member 78 exhibits sufficient
elasticity such that the inner cuff 71 remains in contact with the
wearer during normal wear, thereby enhancing the barrier properties
of the inner cuff 71. The elastic member 78 may be connected to the
flap at opposing longitudinal ends. The flap may be folded over
onto itself so as to encircle the elastic member 78.
The inner cuff 71 and/or outer cuff 74 may be treated, in full or
in part, with a lotion, as described above with regard to
topsheets, or may be fully or partially coated with a hydrophobic
surface coating as detailed in U.S. application Ser. No.
11/055,743, which was filed Feb. 10, 2005. Hydrophobic surface
coatings usefully herein may include a nonaqueous, solventless,
multicomponent silicone composition. The silicone composition
includes at least one silicone polymer and is substantially free of
aminosilicones. A particularly suitable hydrophobic surface coating
is available from Dow Corning MI, Salzburg as supplier code
0010024820.
EXAMPLES
TABLE-US-00002 Air 32 dyne Opacity Permeability WVTR Hydrohead
Strikethrough % m.sup.3/m.sup.2/min g/m.sup.2/24 hrs mbar Sec Outer
Inner Outer Inner Outer Inner Outer Inner Outer Inner Product Lot
No. Cuff Cuff Cuff Cuff Cuff Cuff Cuff Cuff Cuff Cuff Prototype NA
58.7 .+-. 37.6 .+-. 26.8 .+-. 36.9 .+-. 5905 .+-. 5224 .+-. 16.8
.+-. 12.3 .+-. 21.0 .+-. 9.2 .+-. N-Fiber 2.2 3.2 5.6 4.6 129 87
2.1 1.3 3.5 1.5 Prototype NA 65.8 .+-. 39.0 .+-. 65.6 .+-. 38.5
.+-. 5748 .+-. 5193 .+-. 16.3 .+-. 10.0 .+-. 15.6 .+-. 7.6 .+-. SMS
1.8 1.0 11.5 3.8 276 145 1.8 1.7 1.9 1.4 Pampers 0089U011390422
80.1 .+-. 38.8 .+-. 2.1 .+-. 56.1 .+-. 4063 .+-. 5252 .+-. >200
6.7 .+-. >100 10.1 .+-. BabyDry 0.4 3.8 1.0 6.3 67 157 0.8 0.5
Luvs 1047U011390518 85.3 .+-. 36.4 .+-. 3.1 .+-. 90.2 .+-. 304 .+-.
5244 .+-. >200 6.5 .+-. >100 11.8 .+-. 1.2 3.4 1.9 9.3 144 26
1.0 1.4 Huggies BI006912B 80.1 .+-. 45.4 .+-. 2.6 .+-. 45.0 .+-.
3673 .+-. 5581 .+-. >200 8.3 .+-. >100 14.3 .+-. Little 1.0
4.2 0.4 15.7 190 90 1.3 3.5 Movers Huggies NM1275U1F0755 72.7.+-.
53.6 .+-. 4.4 .+-. 145.2 .+-. 375 .+-. 5688 .+-. >200 9.2 .+-.
>100 14.6 .+-. Supreme 2.2 2.3 1.1 23.2 77 85 1.8 3.1 * Results
are expressed as the average .+-. one standard deviation *
Prototype N-Fiber is a 13 gsm SMNS available from Polymer Group Inc
* Prototype SMS is a 15 gsm SMS (Spunbonded-Meltblown-Spunbonded)
nonwoven available from Fibertex under the Comfort Line
Test Methods: Opacity Method
Opacity is measured using a 0.degree. illumination/45.degree.
detection, circumferential optical geometry, spectrophotometer with
a computer interface such as the HunterLab Lab Scan XE running
Universal Software (available from Hunter Associates Laboratory
Inc., Reston, Va.) or equivalent instrument. Instrument calibration
and measurements are made using the standard white and black
calibration plates provided by the vendor. All testing is performed
in a room maintained at 23.+-.2.degree. C. and 50.+-.2% relative
humidity.
The spectrophotometer is conFIG.d for the XYZ color scale, D65
illuminant, 10.degree. standard observer, with UV filter set to
nominal. The instrument is standardized according to the
manufacturer's procedures using the 0.7 inch port size and 0.5 inch
area view. After calibration, the software is set to the Y opacity
procedure which prompts the operator to cover the sample with
either the white or black calibration tile during the
measurement.
Articles are pre-conditioned at 23.degree. C..+-.2.degree. C. and
50%.+-.2% relative humidity for two hours prior to testing. To
obtain a specimen, the article is stretched flat on a bench, body
facing surface upward, and the total longitudinal length of the
article is measured. A testing site on the inner and outer cuffs is
selected at the longitudinal midpoint of the article. Using
scissors, a test specimen is cut 60 mm long by the entire height of
the inner cuff centered at the longitudinal midpoint of the left
cuff. Next, a second test specimen is cut, this time from the outer
cuff, 60 mm long by the entire height of the outer cuff, centered
at the longitudinal midpoint of the left outer cuff. In like
fashion, inner and outer cuff specimens are prepared from the cuffs
on the right side of the article.
The specimen is placed over the measurement port. The specimen
should completely cover the port with the surface corresponding to
the inner-facing surface of the cuff directed toward the port. The
specimen is gently extended until taut in its longitudinal
direction so that the cuff lies flat against the port plate.
Adhesive tape is applied to secure the cuff to the port plate in
its extended state for testing. Tape should not cover any portion
of the measurement port. The specimen is then covered with the
white standard plate. A reading is taken, then the white tile is
removed and replaced with the black standard tile without moving
the specimen. A second reading is taken, and the opacity is
calculated as follows: Opacity=(Y value.sub.(black backing)/Y
value.sub.(white backing)).times.100
Specimens from five identical articles (10 inner cuff (5 left and 5
right) and 10 outer cuff (5 left and 5 right)) are analyzed and
their opacity results recorded. The average opacity for the inner
cuffs and the outer cuffs are calculated and report separately,
each to the nearest 0.01%.
Water Vapor Transmission Rate Method
Water Vapor Transmission Rate (WVTR) is measured using the wet cup
approach. A cylindrical cup is filled with water, maintaining a
constant headspace between the water surface and a specimen sealed
over the cup's upper opening. The vapor loss is measured
gravimetrically after heating the assembled cup for a specified
time in an oven. All testing is performed in a room maintained at
23.degree. C..+-.2.degree. C. and 50%.+-.2% relative humidity.
Articles are preconditioned at 23.degree. C..+-.2.degree. C. and
50%.+-.2% relative humidity for two hours prior to testing. The
article stretched flat on a bench, body facing surface upward, and
the total longitudinal length of the article is measured. A testing
site on the inner and outer cuffs is selected at the longitudinal
midpoint of the article. Using scissors, a test specimen is cut 60
mm long by the entire height of the inner cuff centered at the
longitudinal midpoint of the left cuff. Next, a second test
specimen is cut, this time from the outer cuff, 60 mm long by the
entire height of the outer cuff, centered at the longitudinal
midpoint of the left outer cuff. In like fashion, inner and outer
cuff specimens from the cuffs on the right side of the article are
prepared.
Glass straight walled, cylindrical vials, 95 mm tall with a 17.8 mm
internal diameter at the opening are used as WVTR test vials. Each
test vial is filled with distilled water accurately to a level 25.0
mm.+-.0.1 mm from the upper lip of the vial's opening. The specimen
is placed, inner-facing surface of the cuff downward, over the
vial's opening. The specimen is gently pulled taut and secured
around the vial's circumference with an elastic band. The specimen
is further sealed by wrapping Teflon tape around the vial's
circumference. A preferred Teflon tape is a thread sealant tape
0.25'' wide available from McMaster Carr (cat. No. 4591K11) or
equivalent. The Teflon tape is applied up to the top edge of the
vial but should not cover any portion of the vial's opening. The
mass of the vial assembly (vial+specimen+sealing tape) is weighed
to the nearest 0.0001 gram. This is the starting mass.
The vial assemblies are placed upright in a mechanical convection
oven (e.g. Lindberg/BlueM oven available from ThermoScientific or
equivalent) maintained at 38.+-.1.degree. C. for 24 hours, taking
care to avoid contact between the water in the vials and the
specimens. After 24 hours has elapsed, the vial assemblies are
removed from the oven and allowed to come to room temperature. The
mass of each vial assembly is measured to the nearest 0.0001 gram.
This is the final mass.
The WVTR is calculated using the following equation:
WVTR(g/m.sup.2/24 hrs)=([starting mass(g)-final mass(g)]/surface
area(m.sup.2))/24 hrs
Specimens from five identical articles (10 inner cuff (5 left and 5
right) and 10 outer cuff (5left and 5 right)) are analyzed and
their WVTR results recorded. The average WVTR for the inner cuffs
and the outer cuffs are each reported separately to the nearest 1
g/m.sup.2/24 hrs.
Air Permeability Test
Air permeability is tested using a TexTest FX3300 Air Permeability
Tester (available from Advanced Testing Instruments, Greer, S.C.)
with a custom made 1 cm.sup.2 circular aperture (also available
from Advanced Testing Instruments) or equivalent instrument. The
instrument is calibrated according to the manufacturer's
procedures. All testing is performed in a room maintained at
23.degree. C..+-.2.degree. C. and 50%.+-.2% relative humidity.
The articles are pre-conditioned at 23.degree. C..+-.2.degree. C.
and 50%.+-.2% relative humidity for two hours prior to testing. To
obtain a specimen, the article is stretched flat on a bench, body
facing surface upward, and the total longitudinal length of the
article is measured. A testing site on the inner and outer cuffs is
selected at the longitudinal midpoint of the article. Using
scissors, a test specimen is cut 60 mm long by the entire height of
the inner cuff centered at the longitudinal midpoint of the left
cuff. Next, a second test specimen is cut, this time from the outer
cuff, 60 mm long by the entire height of the outer cuff, centered
at the longitudinal midpoint of the left outer cuff. In like
fashion, inner and outer cuff specimens are prepared from the cuffs
on the right side of the article.
The specimen is centered over the measurement port. The specimen
should completely cover the port with the surface corresponding to
the inward-facing surface of the cuff directed toward the port. The
specimen is gently extended in its longitudinal direction until
taut so that the cuff lies flat across the port. Adhesive tape is
applied to secure the cuff across the port in its extended state
for testing. Tape should not cover any portion of the measurement
port. The test pressure is set to allow air to pass through the
specimen. For non-woven cuffs the pressure is typically set for 125
Pa and for cuffs containing films typically 2125 Pa is used. The
sample ring is closed and the measuring range is adjusted until the
range indicator shows green to indicate that the measurement is
within the accepted limits of the instrument. The air permeability
is recorded to the nearest 0.1 m.sup.3/m.sup.2/min.
Hydrostatic Head Test
Hydrostatic head is tested using a TexTest FX3000 Hydrostatic Head
Tester (available from Advanced Testing Instruments, Greer, S.C.)
with a custom made 1.5 cm.sup.2 circular measurement port (also
available from Advanced Testing Instruments). Two annular sleeve
rings, the same dimensions as the gaskets around the measurement
ports, are cut from the standard protective sleeves for fine
nonwovens (part FX3000-NWH, available from Advanced Testing
Instruments). The sleeve rings are then adhered with two-sided
adhesive tape to the sample facing surfaces of the upper and lower
gaskets of the TexTest instrument to protect the specimen during
clamping. Standardize the instrument according to the
manufacturer's procedures. All testing is performed in a room
maintained at about 23.degree. C..+-.2.degree. C. and about
50%.+-.2% relative humidity.
Precondition the articles at about 23.degree. C..+-.2.degree. C.
and about 50%.+-.2% relative humidity for two hours prior to
testing. To obtain a specimen, lay the article stretched flat on a
bench, body facing surface upward, and measure the total
longitudinal length of the article. Select a testing site on the
inner and outer cuffs, at the longitudinal midpoint of the article.
Using scissors cut a test specimen 70 mm long by the entire height
of the inner cuff centered at the longitudinal midpoint of the left
cuff. Next cut a second test specimen, this time from the outer
cuff, 70 mm long by the entire height of the outer cuff, centered
at the longitudinal midpoint of the left outer cuff. In like
fashion, prepare inner and outer cuff specimens from the cuffs on
the right side of the article.
Place the specimen centered over the port of the upper test head.
The specimen should completely cover the port with the surface
corresponding to the outward-facing surface of the cuff directed
toward the port (inner-facing surface will then be facing the
water). Gently extend the specimen taut in its longitudinal
direction so that the cuff lies flat against the upper test plate.
Adhesive tape is applied to secure the cuff to the test plate in
its extended state for testing. Tape should not cover any portion
of the measurement port.
Fill the TexTest syringe with distilled water, adding the water
through the measurement port of the lower test plate. The water
level should be filled to the top of the lower gasket. Mount the
upper test head onto the instrument and lower the test head to make
a seal around the specimen. The test speed is set to 3 mbar/min for
samples that have a hydrostatic head of 50 mbar or less and a speed
of 60 mbar/min for samples with a hydrostatic head above 50 mbar.
Start the test and observe the specimen surface to detect water
droplets penetrating the surface. The test is terminated when one
drop is detected on the surface of the specimen or the pressure
exceeds 200 mbar. Record the pressure to the nearest 0.5 mbar or
record as >200 mbar if there was no penetration detected.
A total of five identical articles (10 inner cuff and 10 outer cuff
specimens) are analyzed and their hydrostatic head results
recorded. Calculate and report the average hydrostatic head for the
inner cuffs and the outer cuffs and report each to the nearest 0.1
mbar.
Low Surface Tension Fluid Strikethrough Time Test
The low surface tension fluid strikethrough time test is used to
determine the amount of time it takes a specified quantity of a low
surface tension fluid, discharged at a prescribed rate, to fully
penetrate a sample of a web (and other comparable barrier
materials) which is placed on a reference absorbent pad.
For this test, the reference absorbent pad is 5 plies of Ahlstrom
grade 989 filter paper (10 cm.times.10 cm) and the test fluid is a
32 mN/m low surface tension fluid.
This test is designed to characterize the low surface tension fluid
strikethrough performance (in seconds) of webs intended to provide
a barrier to low surface tension fluids, such as runny BM, for
example.
Lister Strikethrough Tester: The instrumentation is like described
in EDANA ERT 153.0-02 section 6 with the following exception: the
strike-through plate has a star-shaped orifice of 3 slots angled at
60 degrees with the narrow slots having a 10.0 mm length and a 1.2
mm slot width. This equipment is available from Lenzing Instruments
(Austria) and from W. Fritz Metzger Corp (USA). The unit needs to
be set up such that it does not time out after 100 seconds.
Reference Absorbent Pad: Ahlstrom Grade 989 filter paper, in 10
cm.times.10 cm areas, is used. The average strikethrough time is
3.3+0.5 seconds for 5 plies of filter paper using the 32 mN/m test
fluid and without the web sample. The filter paper may be purchased
from Empirical Manufacturing Company, Inc. (EMC) 7616 Reinhold
Drive Cincinnati, Ohio 45237.
Test Fluid: The 32 mN/m surface tension fluid is prepared with
distilled water and 0.42+/-0.001 g/liter Triton-X 100. All fluids
are kept at ambient conditions.
Electrode-Rinsing Liquid: 0.9% sodium chloride (CAS 7647-14-5)
aqueous solution (9 g NaCl per 1 L of distilled water) is used.
Test Procedure
All testing is performed in a room maintained at about 23.degree.
C..+-.2.degree. C. and about 50%.+-.2% relative humidity. The
Ahlstrom filter paper and test articles are conditioned in this
controlled environment for 24 hours and 2 hours before testing.
Ensure that the surface tension is 32 mN/m+/-1 mN/m. Otherwise
remake the test fluid. Prepare the 0.9% NaCl aqueous electrode
rinsing liquid. Ensure that the strikethrough target (3.3+/-0.5
seconds) for the Reference Absorbent Pad is met by testing 5 plies
with the 32 mN/m test fluid as follows: Neatly stack 5 plies of the
Reference Absorbent Pad onto the base plate of the strikethrough
tester. Place the strikethrough plate over the 5 plies and ensure
that the center of the plate is over the center of the paper.
Center this assembly under the dispensing funnel. Ensure that the
upper assembly of the strikethrough tester is lowered to the
pre-set stop point. Ensure that the electrodes are connected to the
timer. Turn the strikethrough tester "on" and zero the timer. Using
the 5 mL fixed volume pipette and tip, dispense 5 mL of the 32 mN/m
test fluid into the funnel. Open the magnetic valve of the funnel
(by depressing a button on the unit, for example) to discharge the
5 mL of test fluid. The initial flow of the fluid will complete the
electrical circuit and start the timer. The timer will stop when
the fluid has penetrated into the Reference Absorbent Pad and
fallen below the level of the electrodes in the strikethrough
plate. Record the time indicated on the electronic timer. Remove
the test assembly and discard the used Reference Absorbent Pad.
Rinse the electrodes with the 0.9% NaCl aqueous solution to "prime"
them for the next test. Dry the depression above the electrodes and
the back of the strikethrough plate, as well as wipe off the
dispenser exit orifice and the bottom plate or table surface upon
which the filter paper is laid. Repeat this test procedure for a
minimum of 3 replicates to ensure the strikethrough target of the
Reference Absorbent Pad is met. If the target is not met, the
Reference Absorbent Pad may be out of spec and should not be used.
After the Reference Absorbent Pad performance has been verified,
nonwoven web samples may be tested. Precondition the test articles
at about 23.degree. C..+-.2.degree. C. and about 50%.+-.2% relative
humidity for two hours prior to testing. To obtain a specimen, lay
the article stretched flat on a bench, body facing surface upward,
and measure the total longitudinal length of the article. Select a
testing site on the inner and outer cuffs, at the longitudinal
midpoint of the article. Using scissors cut a test specimen 70 mm
long by the entire height of the inner cuff centered at the
longitudinal midpoint of the left cuff. Next cut a second test
specimen, this time from the outer cuff, 70 mm long by the entire
height of the outer cuff, centered at the longitudinal midpoint of
the left outer cuff. In like fashion, prepare inner and outer cuff
specimens from the cuffs on the right side of the article. Place
the specimen centered over the port of the strike through plate.
The specimen should completely cover the port with the surface
corresponding to the body-facing surface of the cuff directed
toward the port. Gently extend the specimen taut in its
longitudinal direction so that the cuff lies flat against the upper
test plate. Adhesive tape is applied to secure the cuff to the test
plate in its extended state for testing. Tape should not cover any
portion of the measurement port. Ensure that the upper assembly of
the strikethrough tester is lowered to the pre-set stop point.
Ensure that the electrodes are connected to the timer. Turn the
strikethrough tester "on" and zero the timer. Run as described
above. Repeat this procedure for three articles. Average the six
values and report as the 32 mN/m low surface tension strikethrough
time to the nearest 0.1 seconds. Blowout Method Test
For this test, a pant type diaper is cut open along the centerline
of the side panels, and a taped type diaper is used unaltered. The
width of the diaper is measured by applying 1.000 kg across the
back waist area. The diaper across the back waist area is clamped
on the last centimeter of the distal edge of the diaper in a flat
jaw 5 cm wide fixture with 1 cm clamping depth on each end parallel
to the centerline. The diaper is hung vertically and a 1.000 kg
weight is attached to an identical clamp at the bottom and the
weight is slowly released (2 seconds to full load). The diaper
width is then measured (5 second after full weight load) from clamp
to clamp and 2 cm are added to the result. The result is rounded to
the next centimeter.
The length of the diaper is measured by applying 0.300 kg
vertically. The diaper is clamped on the centerline on the last
centimeter of the back waist edge of the diaper in a flat jaw 15 cm
wide fixture with 1 cm clamping depth on each end perpendicular to
the centerline. The diaper is hung vertically and a 0.300 kg weight
is attached to an identical clamp at the bottom and the weight is
slowly released (2 seconds to full load). The diaper length is
measured (5 second after full weight load) from clamp to clamp and
2 cm is added to the result. The result is rounded to the next
centimeter.
A trough 500 is made from a rectilinear block of ridged material
(e.g., nylon) with a flat planar upper surface 502 having a width
of at least those of the diaper measured above and a length of 10
cm more than that of the diaper measured above and at least 5 cm
deep. A channel 504 is machined into the block and the channel runs
down the middle length of the entire trough 500 as shown in FIG.
19. The cross section of the channel 504 is a portion of a circle
with a radius R=12.70 cm. The width W of the channel 504 measures
10.16 cm and the depth D of the channel 504 measures 2.54 cm.
The saline to be used in the blowout method test is prepared by
dissolving 9 g of NaCl in 1000 ml of distilled water. The
artificial BM is a 0.5% aqueous solution of Lubrizol 981 (a.k.a.,
Carbopol). One thousand grams of artificial is prepared by the
following method:
Ingredients:
1. 5.0 g+/-0.1 g of Carbopol 2. 945.0 g+/-0.1 g of distilled water
in a 2000 ml beaker 3. 50.0 g+/-0.1 g of 1M NaOH solution 4. Food
coloring, Kroger.RTM. Brand or equivalent (ingredient list for
Kroger Brand food colorant is water, propylene glycol, yellow 5,
red40, blue1 citric acid, sodium benzoate) Production Method: 1.
Take the 2000 ml beaker with the distilled water and insert a
stirrer, (e.g., 3 bladed propeller with 55 mm diameter) such that
the propeller is 2 cm below the surface of the water. 2. Begin
stirring the distilled water at 1100 rpm 3. Add all of the Carbopol
uniformly over 10 seconds 4. Continue stirring at 1100 rpm for 30
minutes 5. Add all of the NaOH-solution uniformly over 10 seconds
6. Add 2 drops of food coloring and keep stirring at 1100 rpm for
30 minutes. The viscosity of the artificial BM must be between 3300
cp and 4800 cp for use in the Blowout method test. To ensure proper
viscosity, quality analysis may be performed on a Brookfield
spindle viscometer (28 Spindle/22.3.degree. C./RPM 600), or
equivalent device. All testing is performed in a room controlled at
23.degree. C..+-.3.degree. C. and 50%.+-.2% relative humidity.
Diaper samples are conditioned at 23.degree. C..+-.3.degree. C. and
50%.+-.2% relative humidity two hours prior to testing.
The diaper is taped down in a flat planar configuration, on the
upper surface of the trough, with the top sheet facing upwards and
the back sheet taut, extended to the above measured dimensions and
fixed with tape. The distal edges are taped and then extended on
the trough to the same width (the taping points are on the flat
part of the trough, in length and width dimensions). The diaper
longitudinal centerline is aligned with the longitudinal center
line 506 of the trough 500. The waist edge of the diaper starts 10
cm inboard from the end of the trough.
Two paper towels are weighed, folded to a 15 cm.times.15 cm
dimension, and positioned flat at the second waist region (i.e.,
the back region of the diaper when applied to a user) of the diaper
with 1 cm of the paper towel tucked between the diaper and the
upper surface of the trough at the second waist region to collect
artificial BM.
For a diaper (clean, unsoiled) with an overall weight of under 30.0
g, use 100.0 ml of saline (two separate 50.0 ml applications) and
100.0 g of artificial BM (one application) for the Blowout method
test, and for a diaper with an overall weight equal to or greater
than 30.0 g, use 150.0 ml of saline (two separate 75.0 ml
applications) and 150 g of artificial BM (one application) for the
Blowout method test.
The artificial BM is measured from the beaker to within +/-0.5 g by
using a syringe equipped with a 5 mm-10 mm wide nozzle. Saline is
measured volumetrically from the beaker to within +/-0.5 g by using
a 100 ml syringe. From the respective syringes, apply the saline
and artificial BM to the application point on the diaper as
follows. The application point for saline and the artificial BM is
the intersection of the longitudinal centerline and the lateral
centerline of the diaper. The first application of saline is
applied at an application rate of 5 ml/second. Wait 60 seconds
after the first saline application is complete. The second
application of saline is applied at an application rate of 5
ml/second. Wait 60 seconds after the second saline application is
complete. The artificial BM is then applied at an application rate
of 10 ml/second. Wait 60 seconds after the artificial BM
application is complete.
A 10.2 cm diameter ball 600 with a transverse axle 602
(approximately 26 cm long.times.1.5 cm diameter) weighing 580 g
total is placed on the first waist region of the diaper so that the
ball is centered in the channel 504 with the axle 602 horizontal
and perpendicular to the longitudinal centerline 506 of the trough
500. The ball 600 with transverse axle 602 is shown in FIG. 20. The
ball 600 is rolled one time towards the second waist region of the
diaper at a rate of 10 cm/second without applying downward pressure
and stopped when the axle is 3.00 cm from the second waist edge of
the diaper. Lift the ball vertically off of the diaper and scrape
all of the artificial BM off the body facing surface of the waist
cuff area (defined as the area consisting of: A. the width of the
chassis in the second waist region by B. the length of 5 cm in the
longitudinal direction inboard from the second waist edge) with a
rigid ruler onto the paper towel. Remove the soiled paper towel and
calculate the amount of leaked artificial BM/saline on the paper
towel by weighing the overall soiled paper towel and subtracting
the original weight of the non-soiled paper towel. This value is
the Blowout Leakage Weight. Calculate the Blowout Percent Leakage
as follows: Blowout Percent Leakage=(Blowout Leakage Weight)/total
weight of BM applied)*100 Calculate the Efficiency Factor as
follows: Efficiency Factor=(Blowout Leakage Weight/Diaper
Weight)*100
Run five complete tests on the same type of diaper (N=5) and report
the average Blowout Leakage Weight and the average Blowout Percent
Leakage and the average Efficiency Factor to within +/-1%.
Packaging:
The absorbent articles of the present disclosure may be placed into
packages. The packages may comprise polymeric films and/or other
materials. Graphics and/or indicia relating to properties of the
absorbent articles may be formed on, printed on, positioned on,
and/or placed on outer portions of the packages. Each package may
comprise a plurality of absorbent articles. The absorbent articles
may be packed under compression so as to reduce the size of the
packages, while still providing an adequate amount of absorbent
articles per package. By packaging the absorbent articles under
compression, caregivers can easily handle and store the packages,
while also providing distribution savings to manufacturers owing to
the size of the packages.
Accordingly, packages of the absorbent articles of the present
disclosure may have an In-Bag
Stack Height of less than about 110 mm, less than about 105 mm,
less than about 100 mm, less than about 95 mm, less than about 90
mm, less than about 85 mm, less than about 80 mm, less than about
78 mm, less than about 76 mm, less than about 74 mm, less than
about 72 mm, or less than about 70 mm, specifically reciting all
0.1 mm increments within the specified ranges and all ranges formed
therein or thereby, according to the In-Bag Stack Height Test
described herein. Alternatively, packages of the absorbent articles
of the present disclosure may have an In-Bag Stack Height of from
about 70 mm to about 110 mm, from about 70 mm to about 105 mm, from
about 70 mm to about 100 mm, from about 70 mm to about 95 mm, from
about 70 mm to about 90 mm, from about 70 mm to about 85 mm, from
about 72 mm to about 80 mm, or from about 74 mm to about 78 mm,
specifically reciting all 0.1 mm increments within the specified
ranges and all ranges formed therein or thereby, according to the
In-Back Stack Height Test described herein.
FIG. 21 illustrates an example package 1000 comprising a plurality
of absorbent articles 1004. The package 1000 defines an interior
space 1002 in which the plurality of absorbent articles 1004 are
situated. The plurality of absorbent articles 1004 are arranged in
one or more stacks 1006.
In-Bag Stack Height Test
The in-bag stack height of a package of absorbent articles is
determined as follows:
Equipment
A thickness tester with a flat, rigid horizontal sliding plate is
used. The thickness tester is configured so that the horizontal
sliding plate moves freely in a vertical direction with the
horizontal sliding plate always maintained in a horizontal
orientation directly above a flat, rigid horizontal base plate. The
thickness tester includes a suitable device for measuring the gap
between the horizontal sliding plate and the horizontal base plate
to within .+-.0.5 mm. The horizontal sliding plate and the
horizontal base plate are larger than the surface of the absorbent
article package that contacts each plate, i.e. each plate extends
past the contact surface of the absorbent article package in all
directions. The horizontal sliding plate exerts a downward force of
850.+-.1 gram-force (8.34 N) on the absorbent article package,
which may be achieved by placing a suitable weight on the center of
the non-package-contacting top surface of the horizontal sliding
plate so that the total mass of the sliding plate plus added weight
is 850.+-.1 grams.
Test Procedure
Absorbent article packages are equilibrated at 23.+-.2.degree. C.
and 50.+-.5% relative humidity prior to measurement.
The horizontal sliding plate is raised and an absorbent article
package is placed centrally under the horizontal sliding plate in
such a way that the absorbent articles within the package are in a
horizontal orientation (see FIG. 21). Any handle or other packaging
feature on the surfaces of the package that would contact either of
the plates is folded flat against the surface of the package so as
to minimize their impact on the measurement. The horizontal sliding
plate is lowered slowly until it contacts the top surface of the
package and then released. The gap between the horizontal plates is
measured to within .+-.0.5 mm ten seconds after releasing the
horizontal sliding plate. Five identical packages (same size
packages and same absorbent articles counts) are measured and the
arithmetic mean is reported as the package width. The "In-Bag Stack
Height"=(package width/absorbent article count per stack).times.10
is calculated and reported to within .+-.0.5 mm.
EXAMPLES
A. A disposable absorbent article for wearing about the lower torso
of a wearer, the disposable absorbent article comprising: a first
waist region, a second waist region, a crotch region disposed
between the first and second waist regions; a first waist edge and
a second waist edge; and a first longitudinal edge and a second
longitudinal edge; wherein the disposable absorbent article
comprises a chassis comprising: 1.) a topsheet; 2.) a backsheet;
and 3.) an absorbent core disposed between the topsheet and the
backsheet; wherein the disposable absorbent article further
comprises a leg gasketing system and at least one waist gasketing
element; wherein the leg gasketing system comprises a web of
material forming an inner cuff and an outer cuff; wherein the inner
cuff comprises an inner cuff folded edge and an inner cuff material
edge and the outer cuff comprises an outer cuff folded edge and an
outer cuff material edge, such that the web of material is folded
laterally inward to form the outer cuff folded edge and folded
laterally outward to form the inner cuff folded edge; wherein the
at least one waist gasketing element has an inboard lateral edge,
an outboard lateral edge, and two longitudinal edges; the at least
one waist gasketing element comprising at least one elastic
material; wherein when tested by a Blowout Method Test as described
herein, the disposable absorbent article has a Blowout Percent
Leakage of less than 9.0%. B. The disposable absorbent article of
Paragraph A, wherein the Blowout Percent Leakage is less than 7.0%.
C. The disposable absorbent article of any one of Paragraphs A-B,
wherein the Blowout Percent Leakage is less than 5.0%. D. The
disposable absorbent article of any one of Paragraphs A-C, wherein
the at least one elastic material of the waist gasketing element is
an elastic strand. E. The disposable absorbent article of any one
of Paragraphs A-D, wherein the waist gasketing element comprises at
least four elastic strands. F. The disposable absorbent article of
any one of Paragraphs A-E, wherein the at least one elastic
material of the waist gasketing element is an elastic film or an
elastomeric nonwoven. G. The disposable absorbent article of any
one of Paragraphs A-F, wherein the outboard lateral edge of the
waist gasketing element is coterminous with the second waist edge
of the disposable absorbent article. H. The disposable absorbent
article of any one of Paragraphs A-G, wherein at least a portion of
the inboard lateral edge of the waist gasketing element is attached
to the leg gasketing system. I. The disposable absorbent article of
any one of Paragraphs A-H, wherein at least a portion of each of
the two longitudinal edges of the waist gasketing element are
attached to the leg gasketing system. J. The disposable absorbent
article of any one of Paragraphs A-I, wherein an entire length of
each of the two longitudinal edges of the waist gasketing element
are attached to the leg gasketing system. K. The disposable
absorbent article of any one of Paragraphs A-J, wherein the waist
gasketing element is attached to the leg gasketing system over
substantially an entire area that the leg gasketing system overlaps
with the waist gasketing element. L. A disposable absorbent article
for wearing about the lower torso of a wearer, the disposable
absorbent article comprising: a first waist region, a second waist
region, a crotch region disposed between the first and second waist
regions; a first waist edge and a second waist edge; and a first
longitudinal edge and a second longitudinal edge; wherein the
disposable absorbent article comprises a chassis comprising: 1.) a
topsheet; 2.) a backsheet; and 3.) an absorbent core disposed
between the topsheet and the backsheet; wherein the disposable
absorbent article further comprises a leg gasketing system and at
least one waist gasketing element; wherein the leg gasketing system
comprises a web of material forming an inner cuff and an outer
cuff; wherein the inner cuff comprises an inner cuff folded edge
and an inner cuff material edge and the outer cuff comprises an
outer cuff folded edge and an outer cuff material edge, such that
the web of material is folded laterally inward to form the outer
cuff folded edge and folded laterally out